In the article picture: Press operator Tuomo Paalijärvi has already become familiar with the new technology.
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.
