– The plant performs well even in early spring when days are bright and cold. The panels are bifacial and also capture light reflected from snow. The best efficiency is achieved in April and May when daylight increases and the air remains cool, preventing the panels from overheating, says Ismo Pitkänen, Managing Director of Pitkäsen Sähköasennus Oy.

Made from our own profiles

The solar power plant was purchased as a turnkey delivery from Pitkäsen Sähköasennus Oy. The subcontractor for the project was Wisol Oy, a company specialised in building solar parks and also a customer of Mäkelä Alu.

– The project was special because solar parks are typically built from steel. We wanted to do things differently and built the support structures entirely from aluminium profiles extruded in our own factory, says Reijo Seppälä, Project Manager responsible for the project at Mäkelä Alu.

The structures were designed based on official strength calculations by an engineering consultancy. The profile design was carried out by our own profile designer Joni Malinen in close cooperation with Wisol, who also handled the mechanical and layout planning of the plant.

– Wisol was also responsible for the on-site installation thanks to their strong expertise in solar field construction, says Ismo Pitkänen.

– The cooperation with both Ismo Pitkänen and Mäkelä Alu was extremely solution-focused. Together we found the right ways to utilise aluminium in the mounting system, says Arto Kurtti, Commercial Director at Wisol Oy.

Supporting energy self-sufficiency

The plant consists of 1488 solar panels and has a maximum output of 952 kWp.

– The plant produces approximately the annual electricity consumption of fifty electrically heated detached houses, says Ismo Pitkänen.

The electricity consumption of Mäkelä Alu’s factory area is still considerably higher.

– The plant naturally does not cover our full consumption, but it is a good step towards improved energy self-sufficiency. Locally generated electricity also supports our green electricity sourcing strategy, says Reijo Seppälä.

The plant is located in a field area behind the extrusion plant and the anodising plant. The same area also contains an energy storage unit that Mäkelä Alu uses on the national reserve market.

– By participating in the reserve market, Mäkelä Alu supports grid balancing and the use of green energy. The energy storage unit acts as a flexibility element when weather-dependent production fluctuates, says Tomi Pilbacka, Development Director at Mäkelä Alu.

Part of the RRF project

The solar power plant is part of Mäkelä Alu’s RRF project. RRF (Recovery and Resilience Facility) is EU funding under the NextGenerationEU programme, granted for green transition projects. In Finland the funding is provided by the Ministry of Economic Affairs and Employment (TEM). Mäkelä Alu’s project began in 2022 and received RRF energy investment support covering 27 percent of the total investment.

DID YOU KNOW?

Mäkelä Alu’s factory area consumes as much electricity annually as a small municipality. The consumption equals that of around 1000 electrically heated detached houses. All the electricity we purchase is emission-free.

Artikkeli Our own solar power plant is built from aluminium profiles julkaistiin ensimmäisen kerran Mäkelä Alu Oy.

Balancing renewable generation capacity with electricity consumption is challenging and requires changes to the electricity grid infrastructure. When it is both windy and sunny, the grid can become overloaded. When it is calm and cloudy, the situation can be the opposite. This creates instability in the electricity grid. One way to support grid stability is through electricity storage systems. We wanted to do our part and take on more societal responsibility as part of the broader energy transition.

– This is why we have decided to invest in our own electricity storage system. The state-owned transmission system operator Fingrid Oyj (Finland’s national grid operator) needs electricity storage capacity. Mäkelä Alu participates in Fingrid’s reserve markets with its electricity storage system, explains Development Director Tomi Pilbacka.

Fingrid Oyj manages and oversees Finland’s national electricity grid at a high level. When a company invests in an electricity storage system, it can make an agreement directly or via an intermediary with Fingrid and sell battery capacity to the so-called reserve markets for various purposes.

– Our factory area already has a robust electrical infrastructure, and this investment allows us to utilise it for purposes other than aluminium profile production, he adds.

Although the storage system is not directly linked to aluminium profile manufacturing, it reflects Mäkelä Alu’s forward-looking and open-minded approach.

– One of our values is Challenging Tomorrow. This investment fits that value very well. Finland will need more electricity storage systems in the future, so participating in maintaining grid stability is also a genuinely responsible choice, adds CEO Marko Orpana.

Part of the RRF project

The electricity storage system is part of Mäkelä Alu’s RRF project. RRF (Recovery and Resilience Facility) funding is part of the European Union’s NextGenerationEU programme, granted for example to green transition projects. The funding in Finland is allocated by the Ministry of Economic Affairs and Employment. Mäkelä Alu’s overall project began in 2022. It has been granted RRF energy investment support covering 27 percent of the total investment value.

Artikkeli We have invested in an electricity storage system julkaistiin ensimmäisen kerran Mäkelä Alu Oy.

– The heat recovery and pump system replaces the use of liquefied gas in the pre-treatment processes of both coating lines. The waste heat is collected from the foundry’s cooling water basin. This water is generated when castings are cooled with water, explains Tomi Pilbacka, Development Manager.

The foundry produces Mäkelä Alu’s own recycled billet by casting recycled aluminium. The idea of capturing heat from the cooling water originated nearly ten years ago.

– Together with the equipment supplier, we explored different possibilities for utilising process waste heat, and this was identified as one of the most promising targets, says Reijo Seppälä, Project Manager.

The system replaces liquefied gas

With the new system in place, the thermal energy recovered from the foundry is used to heat the pre-treatment water in both coating lines and the horizontal coating line. Before powder coating, the aluminium profiles are washed – previously, this process water was heated with liquefied gas.

– Once the new system is fully operational, we’ll be able to eliminate the use of liquefied gas in these heating needs, Pilbacka states.

Since cooling water is only generated when casting is in progress, the system includes an electric backup boiler that operates with clean electricity.

Container solution allows mobility

The equipment was installed in a separate container that was preassembled at the factory. On site, piping and electrical work was carried out by local contractors.

– This solution is cost-efficient and, if needed, movable. Commissioning is still ongoing, but the system will be fully up and running shortly, Seppälä says.

The equipment supplier was the Finnish company Calefa, specialised in heat pump solutions, and the project was also carried out in cooperation with local piping and electrical companies.

The solution will result in a reduction of 290 tonnes of CO₂ emissions already this year. The investment is valued at approximately €360,000 and will bring substantial energy savings by eliminating liquefied gas usage.

The foundry heat recovery project is part of a larger investment programme aimed at reducing CO₂ emissions from our own production. The project received energy investment support (RRF) from the Ministry of Economic Affairs and Employment of Finland.

Artikkeli Foundry’s waste heat used for heating paintshops julkaistiin ensimmäisen kerran Mäkelä Alu Oy.

On Press Line 3, the billet heating system was upgraded by replacing gas-powered equipment with modern, electric-powered technology. The project involved installing a resistance furnace and an induction furnace for heating billets, as well as renewing the billet table and saw.

Although the principle of billet heating remains the same as before, the solution implemented at Mäkelä Alu includes a section that is the first of its kind in the world.

– What makes this unique is that resistance furnaces have never before been used prior to an induction furnace. The resistance furnace, also known as EHKO (electrically heated high-speed convection furnace), provides the initial heat to the billet. The induction furnace then ensures the precise temperature and the temperature difference between the front and rear ends of the billet, explains profile production development engineer Jan Rintala.

Energy efficiency and more consistent quality

Billets at P3 are now heated more efficiently compared to the previous gas-powered system. The overall efficiency of the system is exceptionally high. The electricity used by Mäkelä Alu is green electricity produced by Väre’s wind power.

– We have also invested in improving the factory area’s electrical infrastructure, which has made it possible for us to carry out electrification projects in the first place, says Mäkelä Alu’s Development Director Tomi Pilbacka.

In addition to the positive environmental impact, the upgrade has other significant benefits.

– The billets now have much more uniform quality for pressing. With a gas furnace, the heat load is concentrated at certain points, which has a major impact on pressing. It is crucial that the billet temperature is consistent. The pressing process is more successful, quality improves, and efficiency increases, summarizes Jan Rintala.

A successful project

The commissioning of the equipment went smoothly. Collaboration with the equipment supplier Extrutec was close throughout the project.

– We planned and reviewed everything very carefully. Everything proceeded smoothly, and the equipment was commissioned on schedule. This is impressive, as no one had previous experience with EHKO, says Jan Rintala.

Press operators are pleased with the new technology. Work has become more efficient, as billets reach the press faster than before.

– There have been no problems with the new equipment; everything has worked extremely well. The equipment is functional and easy to use, states press operator Tuomo Paalijärvi.

Improved working conditions

The new equipment has also had an impact on working conditions. The project included intentional improvements to the working environment.

– The gas furnace produced much more heat, making the hall quite hot in the summer. The electric furnaces do not generate heat in the same way, notes Tuomo Paalijärvi.

The new, larger, air-conditioned, and soundproofed workspace has also received positive feedback.

– This is pure luxury! Operators can now do their work here, whereas previously, the control desks and screens were located outside the soundproofed space in the hall. The hall is very noisy, so this significantly improves working conditions, says Tuomo Paalijärvi.

Additional soundproofed workspaces will also be introduced in other areas of the press shop, such as near the saw.

The modernization of the P3 line is part of a larger investment plan aimed at reducing the company’s CO2 emissions from production. The project has received energy investment support (RRF) from the Finnish Ministry of Economic Affairs and Employment (TEM). We previously reported on this investment in the article: Production line modernisation reduces CO2 emissions by 920 tons.

Artikkeli First in the world: P3’s upgrade exceeded expectations julkaistiin ensimmäisen kerran Mäkelä Alu Oy.

In addition to basic powder-coating, two-colour powder coatings and various types of piece goods are also surface treated in our horizontal powder-coating paint shop.

New paint booth

Our latest investment is a new paint booth, which was installed in January. The equipment in the paint shop was reaching the end of its life cycle and it was becoming difficult to find readily available spare parts. The new paint booth allows us to paint smaller batches cost-effectively.

“The new paint booth supports our company’s strategy. At the vertical powder-coating paint shop, it is possible to change the paint colour in one booth while another booth is being used for painting. Thanks to the new paint booth, this is now also possible at the horizontal powder-coating shop. In this way, the new paint booth minimises product changeover time and allows for the flexible and cost-effective surface treatment of even small batches,” says Development Engineer Jarno Kolkka.

The new equipment is state-of-the-art.

“The investment will improve the surface quality of the coating. In the new equipment, user-friendliness has been taken into account in a completely different way than in the old equipment. The new paint booth will be smoother and easier for our coating team to use,” he continues.

Modernised pre-treatment

Last year, the control system for the washing end in our horizontal line was completely overhauled. At the same time, the production area was fenced off to increase safety. The robot’s working area and the pre-washing basins for the profiles are fenced so that if someone enters the area, the robot stops.

“The automation that controls the equipment and its components was also reaching the end of its life. The old equipment was unreliable and caused a risk of failure, which is why the entire control system and all its cabling were replaced,” says Jarno Kolkka.

The renovation brought the safety of the equipment up to the level required by the current Machinery Directive.

“This stage is critical to the success of the powder coating, so the modernisation also reduced the variation in the pre-treatment of the profiles,” he adds.

Efficient paint removal

A few years ago, a paint stripping line was installed at the washing end of the horizontal line, which was also a major development. The paint stripping line can be used to remove the powder coating from profiles that have been coated incorrectly and return them for recoating.

The paint stripping line saves time, material, money, and the environment, and improves delivery reliability. Before the paint stripping line, coated profiles with colour or surface defects had to be completely scrapped and could not be reused in any way.

Improved air quality

At the end of last year, a ventilation upgrade was also started in the horizontal powder-coating paint shop. The paint shop has open pre-treatment basins and a paint stripping basin. These cause some evaporation and odour problems. Air quality measurements in the horizontal powder-coating paint shop have shown that the air is clean enough, but also that the ventilation in the space is inadequate.

“Ventilation has now been completely renewed in the pre-treatment areas. The pre-treatment and paint stripping line was upgraded with proper local extraction equipment to remove fumes and odours from the space. The system also brings fresh replacement air into the hall from outside,” says Vesa Saarenlaita Production Manager of the surface treatment.

An important objective of the renovation is to improve working conditions and wellbeing at work. Proper ventilation improves both comfort and safety.

The total value of the investments is around EUR 1 million.

Artikkeli Investments in the renovation of the horizontal powder-coating paint shop julkaistiin ensimmäisen kerran Mäkelä Alu Oy.