Rehabilitation and Expansion of the Jooybar Luleh Pipe & Profile Factory
1379–1381 / 2000–2002|1387–1395 / 2008–2016
From restoring existing lines and expanding production halls to the design, manufacture, installation and commissioning of a dedicated Direct-Forming ERW line.
Project LocationJooybar, Mazandaran, Iran
Aftabgoon RoleIndustrial consulting, expansion design and execution, manufacturing and commissioning supervision
Core TechnologyDirect-Forming ERW with size change without replacing forming rolls
Engagement PeriodsTwo separate periods, from consulting through factory management
First Engagement Period
First Engagement Period
Reza Monadi's collaboration with the Jooybar Luleh pipe and profile factory began in 1379 (2000). His role was defined from the outset as consultant, focusing on understanding production issues, assessing factory conditions, and providing practical operational and management solutions. This first period continued through 1381 (2002), creating direct familiarity with the production structure and the factory's needs and providing a foundation for a later return to the expansion project.
Jooybar Luleh pipe and profile factory in Mazandaran, from the early years of the consultant's collaboration with the factory.
Second Engagement Period
Second Engagement Period
In 1387 / 2008, the collaboration entered a new phase. Aftabgoon, under the management of Reza Monadi, served as consultant for the expansion program, responsible for reviewing the existing lines, defining the development path, and designing and executing the direct-forming square and rectangular tube production project. After assessment and improvement of the existing lines, the factory expansion program moved forward with new production-hall layouts, infrastructure design, and selection of an advanced, highly mechanized production line.
The consulting scope covered technical review of machinery and accessories, manufacturing-quality supervision, planning for auxiliary-equipment procurement, review of electrical and mechanical utilities, contractor control, project scheduling, supervision of installation and commissioning, and periodic reporting.
Workforce & TrainingRecruitment of specialist personnel and continuous training of production staff in parallel with the expansion program.
Production Control & MaintenanceEstablishment of structured material and production control, together with preventive and essential maintenance routines for machinery and production monitoring.
Fabrication & Repair WorkshopCreation of in-house capability to produce selected critical parts, including required forming rolls, and to perform repairs within the factory.
Consulting & Existing-State ReviewProduction, equipment and expansion needs
Design & InfrastructureProduction halls, line layout and foundations
Manufacture & CommissioningSupplier selection, manufacturing supervision, installation and trial production
Factory ManagementRole changed after line commissioning; exact dates are not stated in this narrative
Supplier Selection and Assessment
Supplier Selection and Assessment
Capability Assessment in China
After reviewing European and Chinese production-line manufacturers and taking Jooybar Luleh's budget into account, Dalian Field was identified as a company with the potential to manufacture the required line. At the consultant's recommendation, an Iranian delegation travelled to China to assess Dalian Field Heavy Machinery and determine whether it could manufacture the machinery required for the project. The purpose of the visit was to evaluate engineering and manufacturing capability, inspect equipment, and confirm that the project's specific technical requirements could be met.
Visit of the Iranian delegation to Dalian Field for supplier capability assessment and feasibility review of the dedicated Jooybar Luleh production line.
Coordination and Design Finalization
After the two sides consolidated their studies and evaluations, coordination meetings continued at the Dalian Field office. The line specifications, equipment arrangement, execution requirements and manufacturing path were reviewed and finalized with the project team.
Coordination meeting at Dalian Field. From left: Alireza Rezaeian Jooybari, founder and board member; Reza Monadi, consultant; and Abdollah Habibi Jooybari, Chairman of Jooybar Luleh.
Manufacturer Presence at the Project Site
Manufacturer Presence at the Project Site
Project Feasibility Review in Iran
Following the initial assessment in China and at the invitation of project consultant Reza Monadi, Gao Guowu, CEO of Dalian Field, travelled to Iran to review actual factory conditions and assess implementation feasibility. The visit examined the production halls, equipment routes, production requirements and practical constraints at the Jooybar site.
Gao Guowu, CEO of Dalian Field, in Iran for feasibility assessment of the Jooybar Luleh project, following an invitation from Reza Monadi.
Presence During Commissioning
During installation and commissioning, the presence of the manufacturer’s team at the factory made it possible to verify equipment performance under actual production conditions, coordinate the line components and resolve technical issues through to trial production.
Gao Guowu, CEO of Dalian Field, at the Jooybar Luleh factory during commissioning of the production line.
Factory Design
Factory Design
The expansion plan considered raw-material flow, equipment positioning, product movement and future development when arranging the production halls. The ERW 60×60 line was then laid out from strip entry through forming, welding, sizing, cutting, transfer and final packing.
Production-hall layout for the factory expansion program.Complete ERW 60×60 production-line layout and equipment sequence.
Supplementary line route. Drawings are shown at a controlled size for readability and can be enlarged by clicking.
Execution Infrastructure
Execution Infrastructure
After the consultant's presence at the factory, execution proceeded on the basis of drawings prepared by the consultant and the machinery manufacturers. The foundation drawing received from Dalian Field became the basis for execution of the production-line foundations.
A qualified contractor was engaged for the foundation works, and the execution stages were supervised by the project consultant.
Overall machinery-foundation drawing and its relationship to the production-line route.
Production hall during foundation execution and preparation of the line route.Continuation of foundation works and preparation for equipment installation.Foundation channels and equipment anchoring points.Circular foundation and machinery installation/anchoring locations.
Project Technical Solution
Project Technical Solution
The objective was not simply to purchase a conventional ERW mill. The new line was required to produce square and rectangular sections directly and to change product size without replacing the forming-roll set. This reduced product-change downtime and significantly increased production flexibility.
Square tube range
20×20 to 60×60 mm
Rectangular tube range
20×30 to 40×80 mm
Strip thickness
1.25 to 3 mm
Design line speed
Up to 80 m/min
Induction welding
Elestar Italy
Automation scope
Forming, welding, transfer, packing and bundle transfer to warehouse
Manufacturing details and the material/brand of components used in the ordered line were reviewed carefully by the project consultant during design, assembly and factory testing in China.
Review of production-line status at the Dalian Field factory by the consultant.
Review of engineering design at the Dalian Field office by the consultant.
Manufacturing and Quality Control
Manufacturing and Quality Control
After the design was finalized, manufacturing began at Dalian Field. The project consultant reviewed fabrication and assembly on several visits so that machinery performance remained aligned with Jooybar Luleh's technical and operational requirements. Before shipment to Iran, the main line sections and the fully automatic packing machine were tested at the manufacturer's factory.
Part of the production-line manufacturing and assembly process.Review of line sections before shipment.Project team during factory testing at the manufacturer.
According to the project records, practical implementation of size change without replacing the roll-forming tooling was also an important engineering development for Dalian Field in this line configuration.
Engineering Cooperation Memento
During the technical collaboration, Dalian Field presented a memento to Reza Monadi in recognition of his participation in the design and execution of the direct-forming tube line with size-change capability without replacing the forming rolls.
Memento presented by Dalian Field to Reza Monadi in China.
Archive 2009 — Packing Machine Test
Archive 2009 — Packing Machine Test
Before shipment to Iran, the final section of the line and the fully automatic packing machine were tested and reviewed at Dalian Field. The archival film documents the consultant's final inspection of this section in 2009.
After manufacturing and factory testing were completed, the equipment was transferred to Iran and installed in the prepared production hall at Jooybar Luleh. Adjustment, coordination and commissioning were carried out with the participation of the project technical teams. The presence of specialist manufacturers and suppliers on site enabled the main line components to be checked under actual production conditions.
Part of the production line after installation and commissioning at Jooybar.
Technical review of the equipment during trial production and final line adjustment.
Product transfer system on the installed line.Transfer and handling section for the finished profiles.Direct-Forming line during trial production.
Archive 2009 — Trial Production
Archive 2009 — Trial Production
The 2009 archival film records the first trial production of the Direct-Forming ERW line at Jooybar Luleh. At this stage, the full line—from forming and welding through transfer and packing—was reviewed under production conditions.
The new line was designed with a high degree of mechanization from forming and welding through final bundle packing and transfer to the warehouse. Based on the project's operating specifications, this structure enabled approximately 120 tonnes of production per working shift with five operators. The line was intended for stable three-shift operation while reducing product-change downtime.
Up to 80m/min design line speed
Approx. 120 tproduction per working shift
5 operatorsfor the defined mechanized structure
3 shiftsdesigned for stable operation
Continuation of Executive Responsibility
Continuation of Executive Responsibility
During the second engagement period, Reza Monadi's role began as consultant for the design and execution of the direct-forming tube line, covering supplier selection and assessment, design, manufacturing, infrastructure preparation, installation and commissioning. After the lines were commissioned, his responsibility changed to factory management. Because this role coincided with other Aftabgoon projects, long-term full-time presence at the factory was not possible.
Conclusion
Conclusion
The Jooybar Luleh project began with understanding factory issues and restoring production, then progressed through infrastructure design, supplier selection and capability assessment, development of a dedicated production line, manufacturing supervision, foundation execution, installation, commissioning and successful production. The result was greater production flexibility, reduced dependence on tooling changes during size change, increased automation, and stronger manufacturing capability.
The project developed across two engagement periods—1379–1381 / 2000–2002 and 1387–1395 / 2008–2016—and documents part of Aftabgoon's track record in industrial consulting, factory development and production-line commissioning.
