Luottamuksesi arvoinen kumppani!

Simetek provided new drive rails and a pulling car for the intermediate thickener at Elementis Minerals’ talc plant in Outukumpu.

Collaboration began in late summer 2020, when Elementis noticed the need for new drive rails and a pulling car for its intermediate thickener at its Outokumpu plant, as the existing ones were nearing the end of their service life. Simetek drew up a preliminary design that was used as the basis to manufacture new rails, and created an installation plan to implement the project.

The intermediate thickener is a round pool around 50 metres in diameter, into which talc’s raw material is pumped. A drive rail goes around the outer edge of the thickener, along which there is a pulling car that powers a mixer steel rake. The car itself features a cogwheel that runs along a steel chain welded onto the top of the drive rail.

The rail pieces were bent using a mangle

“Designer Matti Hirvonen went to laser scan the intermediate thickener at the start of the project to obtain precise information about the dimensions of the old rails, the roundness of the rails, and the evenness of the surface on which the rail runs. Based on the scanning data, we then designed and manufactured new rails and a new frame for the pulling car. The scanning data also gave us the installation height for the new rails so that all of the surfaces are at the same height,” explains project manager Ville Kinnunen.

Improvements were made to the new pulling car, including to the structure, location, and adjustability of the adjustable wheels. The car was also made lighter.

The pieces for the rail arrived at the machine shop as 12-metre-long beams. According to Kinnunen, bending them to the right radius required special expertise with mangling thick beams and flame straightening.

“If you heat the beam in certain places, you can make it bend in the right direction. You don’t learn this sort of thing from books; our veteran machine shop workers have learnt to judge by eye where the beam needs to be heated in order for it to bend in the right direction a couple of metres further along.”

Collaboration went smoothly

Collaboration between Simetek and Elementis was smooth right from the start. Simetek knew what the customer wanted at every stage of the project. Elementis meanwhile was able to trust that Simetek would fulfil their wishes.

The installation of the drive rails went without a hitch. Simetek carried out the work in two 12-hour shifts, each worked by five men. Even though it sleeted and rained, the work groups were in good spirits.

“We would like to thank the customer for good break facilities and a good installation environment. This was a real success story. Contact with the customer went well, and they had carried out the requested preparations so that we were able to start installation immediately after arriving on site,” says Kinnunen.

A KA1160 conveyor deployed in the late 1970s at Yara’s Siilinjärvi mine required modernisation as it was still using the original drive gears and power industrial gearbox. Simetek Works implemented a modernisation project from mechanical engineering to installation.

The KA1160 transports crushed stone from the gyratory crusher to a day silo, from where it is transported using a conveyor to a fine crusher. The conveyor lifts material a total of 75m from below ground to the top of the silo and transports it a length of 390 metres. The conveyor capacity is 2000 tonnes per hour.

“This is our production plant’s largest conveyor, and from a technical standpoint, it is a demanding project with its dual use. It was nice to see that a local service provider was able to offer and implement a functional solution,” says Yara’s maintenance manager Anssi Pietarinen.

The conveyor’s pulley drive was modernised, in practice by adding two new gears and new beds for the gears and electric motor. Alongside another gearbox, a maintenance platform was also manufactured to make maintenance easier.

“Planning the modernisation required strength calculations and the redimensioning of the gears in order for the conveyor to be able to withstand the current load, and a possible increase in capacity. Before planning, the conveyor’s pulley was laser scanned so that we could use the scanning data to design modification drawings,” says design manager Pasi Knuuttila from Simetek.

Installation was carried out on a tight schedule

Simetek designer Matti Hirvonen designed the new components for the pulley and also acted as installation foreman in the project.

“I was able to make quick decisions during the installation phase as I acted both as designer and installation foreman. I knew what the next work phase was without looking at the images. I also knew the dimensions off by heart, which meant that the installation moved swiftly forward,” says Hirvonen.

Good preparation is key to the success of an installation. Hirvonen gathered all of the required supplies in the week prior to the installation, so there were no unnecessary trips to the machine shop to pick up components.

The installation also required a tight schedule. The old equipment had to be disassembled and new ones installed in the space within a week. Hirvonen is grateful for the good work group involved in the installation. There was a good atmosphere in the installation team, and we were all left with a positive impression.

“I was tightening bolts and acting as a hot work guard just like everyone else. I didn’t just stand there with my hands behind my back wearing a hard hat,” Hirvonen laughs.

Yara’s project manager Mikko Lappalainen also appreciates the smooth installation. It did not require much of his attention, so he was able to focus on other projects.

“All in all, the design and implementation of the modernisation took our wishes and perspectives into account excellently. We worked together to find a suitable implementation solution. Of course, our operating environment and working methods are familiar to Simetek, who helped in the matter.”

“Simetek provided excellent mechanical engineering”

Anssi Pietarinen explains the background to the investment, which was that the old equipment had reached the end of its service life. Maintenance costs had risen so high that Yara decided it would be sensible to invest in a new conveyor to replace the old one. Increasing reliability and safety, and reducing maintenance costs were also contributing factors to the decision.

Yara also wanted to add frequency converters to the conveyor, which would enable the specification of the belt speed. They would also help to move away from fluid couplings. The frequency converters also meant that it was easier to service the equipment and, if necessary, the conveyor’s capacity can be raised by increasing the belt speed.

Simetek handled the mechanical engineering of the conveyor excellently. We were pleased with the technical solution they offered. It was a plus that they have a machine shop and design department all under the same roof. That makes service more cost-efficient and transparent towards the customer. “We always know what’s going on and where we are,” says Pietarinen.

He also appreciates that Simetek is able to handle the entire chain without subcontracting. The machine shop can handle machining, welding, edging, and, if necessary, flame-cutting. Pietarinen says that Simetek’s own installation engineers and foremen bring cost-efficiency, high quality, and safety to installations.

“The project progressed on schedule. We made small detail changes during the installation, but they were also a success. The collaboration between Simetek and the electrical contractor was also seamless. We were able to test run the equipment on schedule. The entire project was delivered excellently,” says Pietarinen.

He is also satisfied that Simetek always submits quotes on time and that they correspond to the request for a quote. They are well-prepared.

“Simetek has been a good supplier to us, and it is close by. They can be here half an hour after calling them, if necessary. That brings flexibility and efficiency to our work. We can get little things moving quickly,” adds Pietarinen.

The discs were made of HB400 wear-resistant steel, and the axle was made of quenched and tempered steel. A work-hardening coating was welded onto the discs, after which they were machined to suit the axle’s tolerances. The rotor’s assembly had to consider the interference fit between the disc and axle by heating and cooling the pieces.

“I continually develop the in-house logistics to make things smoother”

Driver and warehouse keeper Hakkarainen made the transition from baker to metal industry worker, and now makes sure that work runs smoothly at Simetek.

Hakkarainen came to Simetek in 2008 after becoming ill with occupational asthma in his work as a baker. He first worked as a flame cutter for five years, and then spent another few years as a welder. His work gradually began to focus more and more on transport and warehousing.

“I am responsible for unloading lorry loads, receiving goods and recording them in the warehouse, for shelving and preparing outgoing goods, for packing, and for transport to nearby areas,” explains Hakkarainen.

A smooth flow of materials and products

Hakkarainen does his bit to ensure that the machine shop runs smoothly and no-one is left twiddling their thumbs. He also continually develops the in-house logistics to make things smoother. The welding shop’s consumables are currently being moved to another location.

“I aim to ensure that materials and products flow like a relay baton from one person to another,” says Hakkarainen.

For material flow, he works closely with Mika Kononov, who is responsible for material procurement and logistics, and with machine shop foreman Ilkka Juutilainen.

“Typically goods deliveries are ordered very close to the product manufacturing date, and we take the correct raw materials to the workpoint so that they are ready for when we start on the commission to make it as easy as possible to begin work,” explains Hakkarainen.

Owners are close to the workers

Hakkarainen’s work requires initiative and quick decision-making – he needs to be acutely aware of the situation. He feels that whether or not his work feels enjoyable is largely down to him.

“For me the most essential thing about work is getting my tasks done well and for everyone to be satisfied. That means us and our customers.”

Hakkarainen has yet to face a job that he and his colleagues could not overcome. Sometimes long and heavy items in packing can be difficult to load onto lorries, but we’ve always managed by working together and being persistent.

Hakkarainen appreciates that Simetek’s owners do not walk around in a suit and tie, and are the same Simetek people as everyone else. Managing director Timo Roivainen is interested in Simetek’s operations and is active in the machine shop. He also says that the workers’ wellbeing is important to Satu Räsänen, who manages HR and finance.

Hakkarainen lives in Maaninka, and often has enough energy left after work to play with his grandchildren, go for walks, and do strength training. He believes that his good level of fitness helps him at work, as he needs to be able to climb up onto 180cm-high vehicle platforms.

We carried out regular maintenance on an energy industry gearbox in early summer. We inspected the condition of the gear, replaced its bearings and seals, and repainted the surfaces of the gearbox. Before we installed int back into place, we test-ran the gearbox at Simetek. The test run checked the operating temperature, seal, and function of the bearings. After we serviced the gearbox, we drew up a report on the maintenance work for the client The maintenance and installation of the gearbox went as planned and according to schedule.

“At Simetek, almost all commissions are almost unique”

Hunting and fishing enthusiast Hannu Petjala has worked as a sheet metal worker at Simetek for 18 years. The old hand is happy to help younger workers if he notices that they have problems completing a job.

Petjala likes that at Simetek he can begin each commission fresh and see the overall result from start to finish as the work progresses.

“This is an interesting place to work because the job isn’t mass production. All of the commissions are almost unique, and even after all these years of experience, I often have work to do that I’ve never done before. I feel that one of my strengths is that I’ve completed challenging tasks – I’ve never thrown in the towel,” says Petjala.

One of the biggest and most challenging projects Petjala was involved in was a component manufactured for a pulp washer a couple of years ago. It required several months of work.

“We just worked together as a group to overcome the challenges,” explains Petjala.

At Simetek, the team examines large projects together with the customer before beginning work. This was also the case for the pulp washer component, and potential problems were mapped in advance. Petjala is grateful that there is good interaction with the design side of things at Simetek.

“Things always go smoothly with our design engineers!”

Experience with a wide range of machine shop work

Petjala has previously worked at Niskametalli, Pielavent, RKP-Konepajat and Upak Oy. At RKP and Niskametall, he carried out heavy machine shop work, while at Pielavent he worked with thin sheet metals and assembly work. At Upak, Petjala’s job description included the manufacture of wood chip boiler systems, wood boilers and even entire wood chip boiler plants, including equipment and housing.

After primary and secondary school, Petjala completed two years of professional training as a sheet metal worker. He laughs that work has taught him the rest.

“I’ve done proficiency tests now and again to keep my welding classes valid.”

Petjala says that there’s always a good atmosphere among colleagues at Simetek, and there have never been any serious disagreements.

In the autumns, Petjala spends time hunting with his two Jämthund dogs and in the winter, he enjoys net fishing. He lives in Maaninka with his wife. They have two adult sons.

We installed steel structure changes in froth flotation cells for GTK Mintec’s Outukumpu test plant. Watch the video to see how everything came together.

Simetek has developed a lot over the years. Jouni Leskinen has worked at Simetek for twenty years, and has seen the company go through different phases while working in a couple of different roles.

Leskinen is a qualified sheet metal worker and at Simetek he works in maintenance and installation. He is responsible for lead burning, a field which has rather few specialists in Finland nowadays.

“Previously, I was a machinist at Simetek. But I found engineering work more enjoyable, as there is more variation in my workday.”

Leskinen learnt machining from a senior foreman at his previous job at Kuuslahden Konepaja. In addition to Kuuslahden Konepaja, he also worked at Savema.

According to Leskinen, Simetek has more commissions from all over Finland now than it did in previous years. He doesn’t feel the need to travel that much anymore, and is happy to carry out maintenance work at Yara, near Simetek.

“I’d rather let the younger ones go travelling,” Leskinen laughs.

You need to be sure of what you’re doing on site

Leskinen mainly services belt, drag chain and material conveyors, containers, and piping. He likes being able to make old things as good as new, and to see the results of his work. The most important thing about work is managing safety.

“It’s easy to hurt yourself or others if you aren’t careful on a work site. Luckily, Simetek invests in safety and emphasises that we need to be sure of what we’re doing.”

Employees are often assigned certain areas on site so that everyone is sure to be familiar with that area’s processes and can work with them. For gig work, Leskinen finds it’s a challenge to learn the house rules, as every company has their own slightly different operating culture.

“We always carry out preparations for work sites so that the workers are informed of what they’re doing. It’s also important to know what machinery we need with us, so that we don’t just drive all the way to Kittilä with just a welding machine and an angle grinder and then realise when we get there that we need a lot more.”

The company tries to finish maintenance and installation work as much as possible in the shop so that only assembly needs to be carried out on site.

Simetek has a great atmosphere

Leskinen describes the atmosphere at Simetek as good; there are shared wellbeing at work days and fishing competitions, and all of his colleagues get on well with one another.

Leskinen, who has seen Simetek go through numerous phases, has watched the company pass down through generations, and finds this positive. Even though change always requires growth, operations have moved forward, and Leskinen says they are constantly improving.

“Nowadays there is more interaction than before, but times have changed of course. We aren’t living in the same world anymore.”

In his free time, Leskinen relaxes with fishing and sports. Last winter he racked up a thousand kilometres skiing.

We manufactured a gas duct curve from acid-resistant steel and an underflow Y-manifold from duplex steel for Agnico Eagle Finland’s Kittilä mine. At the same time we supplemented the customer’s warehouse with a few corresponding parts.

Simetek’s paint shop operates in connection with Simetek’s machine shop, and is one of the largest in Siilinjärvi. It carries out surface treatment work for its own projects and for subcontracted work.

The paint shop pays particular attention to quality assurance. Before painting, we check the object for any welding defects, spatter, or anything else that needs repairing. After painting, we test the thickness of the paint film to ensure that the treated product definitely fulfils the customer’s wishes,” explains surface treatment worker Sanni Tikkanen.

Surface treatment for large objects

Simetek is able to provide surface treatment even for large objects. The paint line consists of a 16-metre-long steel grit blasting chamber, a 24-metre-long wet painting chamber, and a packing department. Large objects can also be conveniently treated using our gantry crane and transfer cars. The lifting capacity is 10 tonnes.

“I began work at Simetek in 2017, and since then the products for painting have only increased in size over the years. The largest objects we’ve painted are Cat mining truck beds, parts for Junttan’s pile-driving machines, steel structures for Bolide’s Kevitsa mine, and a mobile crusher, which is a crusher built on the trailer of a truck,” says Tikkanen.

In addition to large products, Simetek also receives various maintenance platforms, cylinders, and even very small objects for painting. The paint shop is “fed” in-house by the welding workshop, but it also takes on subcontracted painting jobs.

“We are able to react quickly to customers’ needs,” says Tikkanen.

Painting aims at wear-resistance

Product surface treatment typically aims to increase resistance against wear and corrosion. Usually, a treated surface must also be able to withstand heat to prevent the sun from burning the paint. It is common to apply a base layer of epoxy paint and a top coat of polyurethane paint. The paints form a film with a good resistance to wear and weather.

“Before painting, we carry out steel grit blasting on products to ensure that we aren’t working with wafer-thin sheeting. Paint adheres significantly better to a steel grit-blasted surface, and blasting also removes impurities from the surface,” explains Tikkanen.

Pressurised air is used to remove dust from the surface before painting and the surface is checked to make sure there is no grease or other dirt. After painting, a record of the painted object is made and the products are packed and sent to the customer.

The paint shop will undergo development as a result of Simetek’s development project, which is due to begin in summer 2021. The paint shop also carries out pickling, which improves the properties of stainless steels and aluminium.