From idle machinery to operational success: customer support at every step

10 Feb 2025

Bruks Siwertell recognizes the critical importance of through-life equipment support and the ability to be by a customer’s side from delivery to end of service life. These journeys are not always simple. Equipment can be delivered and then the operational landscape can dramatically change. A commitment to through-life customer support means helping customers respond to shifting market demands. 

A notable example of this is Bruks Siwertell’s ongoing collaboration with Boliden Tara Mines at Dublin Port in Ireland, highlighting how tailored service support has enabled this customer to achieve operational success following an operational pause.

Operating in highs and lows

Acquired by Swedish company, Boliden AB, in 2004, Boliden Tara Mines is one of Europe’s largest zinc mines. Located near Navan, in County Meath, Ireland, the 1,000m-deep facility has been producing zinc and lead concentrates since 1977. However, falling metal prices in 2023 saw the producer suspend production, and mid-last year, operations were resumed. 

So where does Bruks Siwertell fit in this picture? In 2019, Bruks Siwertell delivered a unique material handling system to serve Boliden Tara Mines’ then new terminal located in Dublin Port’s Alexandra Basin. 

The contract presented a complex set of challenges, from material-specific, to architectural and environmental constraints. Working together with the operator, Bruks Siwertell developed a totally new system, comprising a double-enclosed belt-type ship loader, with luffing and slewing capabilities, a reversible shuttle-belt conveyor, with double-embedded covers, and dual remotely-operated connection points, as well as a double-enclosed jetty and overland conveyor. The conveyor and its walkways are also embedded. 

Zinc and lead can be extremely hazardous, and as the equipment is only 150m away from a popular docklands area, close-to-zero dust emissions were stipulated in the initial contract. A bespoke dust extraction system was designed, involving initially filtered, clean air being passed through a second filtration unit with special high-particulate air (HEPA) filters.

Lead and zinc are also very sticky materials. To stop material clogging up the loader, it was designed with rounded corners, which prevent any ore build-up. Other measures included specialized plastic chute liners; all designed to keep the material flowing. The system is capable of loading ships of up to 10,000 dwt at a continuous rated capacity of 600t/h. 

The pause in the company’s operations meant that this equipment had been idle for fourteen-months and its original operating crew, and their specific knowledge of this unique ship loader, was no longer available. When this happens, new operators need to be trained and the equipment needs to be inspected to ensure that it meets current standards. 

Comprehensive training programs 

In November 2024, Bruks Siwertell delivered an intensive training program at Dublin Port. The facility’s new workforce needed to familiarize themselves with the Siwertell ship loader and its conveyors; critical to ensuring the safe and efficient start-up of operations and ongoing success.

The training covered safety protocols, operational procedures, and maintenance essentials. Despite an expedited schedule of one and a half days, the operators quickly grasped the most essential details of handling the loader and its automatic coupling technology to the shuttle conveyor. A subsequent sand test verified that all links in the transport chain functioned as intended, further preparing the team for ship loading operations.

Customized support for unique challenges

Technical support is the backbone of uninterrupted operations. Following training, Bruks Siwertell’s team provided on-site supervision for Boliden’s first and second ship loading operations after the facility’s reopening.

Overcoming the challenges of minor technical issues, a new workforce, weather delays, and complex operational requirements, the facility has now successfully loaded thousands of tons of dry bulk material. Operators have become proficient in managing the advanced equipment, and the system has proven its reliability and efficiency in real-world conditions.

For instance, during the first ship loading operation in December 2024, operators successfully loaded over 5,100 tons despite rain delays and an initial sensor malfunction. By the time the second ship arrived two weeks later, the team operated the system independently, loading 4,719 tons seamlessly. 

Between loading sessions, Bruks Siwertell inspected the loader and conveyor systems, and electrical systems, addressing issues such as dust  and material build-up, corrosion, and minor leakages. Preventive maintenance recommendations, like applying corrosion-protective paint and adjusting the storm lock tower, were made to extend the equipment’s lifespan and improve efficiency. By addressing minor issues, equipment can perform optimally for years to come.

Advancing sustainability goals

The Boliden ship loader demonstrates the capability of Bruks Siwertell to meet a highly specific, very strict environmental agenda, with the system’s triple-enclosed design, minimizing dust emissions, and the two-stage filtration process, including HEPA filters, ensuring a near-zero particulate release into the atmosphere.

These measures help customers achieve their environmental objectives without compromising operational performance. But further to this, ongoing service support offers inherent sustainability, as equipment has longevity built-in; nothing is replaced unnecessarily, or to the detriment of the environment. 

A Dublin Port success story

Boliden’s facility at Dublin Port exemplifies the value of investing in Bruks Siwertell equipment and the ongoing customer service that is available from day one of a delivery. As Boliden continues its operations, Bruks Siwertell will remain a dedicated partner, offering ongoing timely support through inspections, maintenance, and further training as needed. 

Bruks Siwertell’s lifetime equipment support empowers customers with the tools and expertise they need to succeed. Whether through tailored training, innovative engineering, or proactive maintenance, we deliver solutions that drive operational excellence and sustainability.