Holistic flowsheet development at Metso: A look inside the Metso Test Center in Pennsylvania and locations around the globe

This article was first published on Global Mining Review in February 2026.

The Metso Test Center (MTC), recently marked its third anniversary since relocating into state of the arts facility in Manchester, Pennsylvania, USA. Over this period, the state-of-the-art facility has evolved into a critical hub for minerals processing innovation, supporting the mining industry with advanced test work capabilities and a strong commitment to operational safety. Originally rooted in grinding technologies, the center has expanded its scope significantly, now offering comprehensive flowsheet testing and contributing directly to improved project outcomes across the mining value chain. 

For Metso’s customers across North America, and globally, the transformation of the MTC represents a significant advantage in mineral processing innovation and safety. By expanding its capabilities to support the full minerals processing flowsheet — including advanced grinding, magnetic separation, and filtration, the center empowers mining operations to optimize project outcomes with greater precision and reliability. The integration of automation, robotics, and a chemistry laboratory ensures that customers benefit from cutting-edge data quality, rapid decision-making, and robust safety standards. 

The MTC supports test work from the very earliest stages of a project, offering customers accurate and reliable data that can be confidently scaled up to full production. With decades of experience and the flexibility to trial various circuit configurations through both bench-scale and pilot-scale testing, the center provides value to a wide range of mining companies — including junior explorers to mid-tier producers and major mining companies. Customers also have the opportunity to visit the facility, observe test work firsthand, and gain deeper insight into the processes being developed. 

This holistic approach not only de-risks project development but also delivers tangible value through improved efficiency, sustainability, and operational excellence, making the Metso Test Center a critical partner for mining companies striving to stay ahead in a competitive and evolving industry. 

"Our test center in Pennsylvania allows us to support mining customers from the very earliest stages of project development. By piloting key Metso technologies such as HRC™ high-pressure grinding rolls, Vertimill® and HIGmill™ stirred mills, we can simulate and optimize complete comminution circuits, maximizing both comminution circuit performance and energy efficiency. This ensures that our customers achieve the best possible process certainty from day one," says Audrey Walters, Director, Process Engineering and Test Center.

Expanding capabilities to support the full minerals processing flowsheet 

The MTC has undergone a strategic transformation, evolving from a grinding-focused facility into a multidisciplinary testing environment capable of supporting full flowsheet development. This includes front-end processes such as HRC™e high pressure grinding rolls (HPGR), followed by dry and wet magnetic separation, grinding and regrinding, and extending to downstream operations like thickening and filtration. The addition of thermal processing capabilities further enhances the center’s ability to replicate real-world mineral processing scenarios. 

One of the most notable advancements has been the recommissioning of a pilot-scale semi-autogenous grinding (SAG) mill. This addition enables simulation of complex grinding circuits under realistic conditions, providing critical data for process design and optimization. The facility has also invested in ultrafine screening and thermal processing capabilities, broadening its scope and enabling flexible testing of various flowsheet configurations. 

The integration of a chemistry laboratory has added a new dimension to the center’s capabilities. This lab supports elemental-level analysis and bench scale flotation test work, enabling more precise characterization of ore samples and enhancing the reliability of test results. These developments allow for a more holistic approach to mineral processing, where each stage of the flowsheet can be tested, optimized, and validated under controlled conditions. 

Embracing automation and digitalization 

To further enhance efficiency and data quality, the MTC is actively integrating automation and robotics into its operations. These technologies are being deployed across various stages of test work, from sample preparation to data collection, with the goal of improving accuracy, repeatability, and safety. 

Automated systems enable real-time data acquisition, which is essential for dynamic process monitoring and rapid decision-making. This digital transformation aligns with broader trends in the mining industry, where data-driven approaches are increasingly used to optimize performance, reduce variability, and support predictive maintenance. 

A culture of safety in complex pilot operations 

Despite the technical complexity and variability of its operations, the MTC has maintained an exemplary safety record. This achievement is underpinned by a proactive safety culture that emphasizes continuous improvement, employee engagement, and rigorous oversight. In a dynamic testing environment where no two programs are alike, Metso’s approach to safety is essential. The ability to identify risks, develop mitigation strategies, and implement practical solutions reflects a deep commitment to operational excellence and employee well-being. 

Looking ahead: continued investment in innovation 

The Metso Test Center future strategy focuses on further strengthening its role as a center of excellence for mineral processing test work. Metso Test Center exemplifies how targeted investment in test work capabilities, combined with a strong safety culture and a commitment to innovation, can deliver tangible value to the mining industry. By enabling comprehensive, pilot-scale testing across the mineral processing flowsheet, the facility supports informed decision-making, de-risks project development, and contributes to the advancement of minerals processing technologies. As the industry continues to evolve, centers like the MTC will play a critical role in shaping the future of mining through technical excellence and operational integrity. 

Strengthening global capabilities: Pori’s Separation laboratory and flotation innovation 

Complementing the advancements at the MTC, Metso has further expanded its global testing infrastructure with the opening of a state-of-the-art Separation laboratory and pilot area at its Research Center in Pori, Finland. This strategic investment reinforces Metso’s commitment to developing advanced flotation and beneficiation solutions, supporting the mining industry with cutting-edge technologies and scalable flowsheet development. 

The new laboratory in Pori centralizes Metso’s latest flotation innovations, including a modular Concorde Cell™ laboratory unit designed for complex test work and R&D. This setup allows for more flexible and efficient testing, enabling faster sample preparation and processing. As a result, Metso can deliver high-quality test work at greater speed, helping customers accelerate project timelines and reduce uncertainty in early-stage development. The latest development at the Pori Separation laboratory is the new coarse particle flotation (CPF) cell, which is set for launch in 2026 following industrial-scale testing. 

A global network of research excellence 

Metso Research Center in Pori is one of Metso’s key hubs for research and product development, specializing in mineral processing, hydrometallurgy, battery material process solutions, and smelting technologies. With a team of around 180 experts and extensive laboratory and pilot plant facilities, the center offers unique capabilities for process flowsheet development and optimization, enabling the creation of efficient and sustainable process solutions. In addition, it provides advanced mineralogical and chemical analysis services, as well as materials research, to support both process solution design and technology development. 

Together with MTC and other strategic locations worldwide, Metso’s research infrastructure forms a robust network that supports bench-to-pilot scale testing, process simulation, and flowsheet optimization. This global reach ensures that customers benefit from consistent, high-quality support regardless of project location or complexity. 

Celebrating a decade of filtration innovation: Dewatering Technology Center 

Further strengthening its global testing capabilities, Metso recently celebrated the 10th anniversary of its Dewatering Technology Center (DTC) in Lappeenranta, Finland. Since its establishment in 2015, the center has become a unique hub of expertise in filtration and separation solutions, supporting customers with advanced R&D, pilot testing, and process optimization. 

Working in close collaboration with Metso’s Filtration Technology Center that specializes in filter manufacturing and also located in Lappeenranta, the DTC has contributed to more sustainable and efficient filtration practices across the industry. Over 90% of Metso’s filters are part of the Metso Plus offering, recognized for their energy-, emissions-, and water-efficiency. 

DTC is part of Metso’s broader filtration expertise, which includes 16 filter types, more than 5,000 global installations, and a robust service network spanning approximately 140 locations. Earlier this year, Metso expanded its filtration manufacturing footprint with the opening of a Dewatering Development Hub in Irapuato, Mexico, further enhancing its global capabilities. 

A future built on innovation, safety, and collaboration 

The transformation of the Metso Test Center, the expansion of the Pori Research Center, and the decade of progress at the Dewatering Technology Center in Lappeenranta collectively reflect Metso’s strategic commitment to advancing minerals processing through innovation, safety, and customer-centric development. These facilities, along with Metso’s global network of testing and manufacturing hubs, form a robust foundation for delivering sustainable, scalable, and high-performance solutions across the mining value chain. 

From grinding and separation to flotation and filtration, Metso’s research and testing ecosystem enables customers to validate process designs under realistic conditions, optimize performance, and reduce project risk. Cross-collaboration and cross-training between all global centers further strengthen this ecosystem, fostering knowledge exchange and accelerating innovation. As the industry continues to evolve, Metso’s integrated approach — combining pilot-scale testing, digitalization, and deep process expertise — will remain a driving force in shaping the future of minerals processing through technical excellence and operational integrity.