Before integration with ME Elecmetal, the Peruvian foundry Funvesa operated with high energy consumption and poorly technologized heat treatment processes, which limited its operational performance and the consistency of the mechanical properties of wear parts.
The Cleaner Production and Resource Efficiency (RECP) diagnosis, dependent on UNIDO (United Nations Industrial Development Organization), developed together with the ZIS (Sustainable Industrial Zones) Peru program, confirmed a critical modernization opportunity in the heat treatment process, a key stage to guarantee the quality, strength, and service life of components used by large-scale Peruvian mining.
Simultaneously, the market demanded:
- Greater durability and technological precision in the parts.
- Advanced engineering, simulation, and performance analysis.
- Reduction of delivery times through strengthened local production.
- Traceability and alignment with ESG standards.
The union between ME Elecmetal and Funvesa, forming ME Elecmetal Funvesa and part of ME Elecmetal South America, allowed addressing all these gaps, transforming the plant located in Callao into a success case of the Sustainable Industrial Zones program (ZIS Peru), implemented by UNIDO and the Ministry of Production of Peru.
Through the ZIS Peru program, a key project was executed: the replacement of two heat treatment furnaces or ovens with a new one, equipped with a heat recovery system, which involved a total investment of about USD 300 thousand, of which 30% was co-financed by the program. The change represented an immediate technological leap:
- Significant reduction in natural gas consumption, thanks to the heat recuperator.
- Operational simplification and ergonomic improvement, reducing exposure to risks and facilitating operation.
- Increased capacity and uniformity of heat treatment, especially for large parts such as mantles and crusher bowls.
- Greater control and repeatability of the process, essential to maintain ME Elecmetal standards in Peru.
Although the financing application occurred before the acquisition, the implementation, commissioning, and final success were achieved under ME Elecmetal’s management, reflecting continuity of purpose between both administrations.
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Quantitative energy and environmental impacts:
- 937 tCO₂eq/year less, equivalent to removing 198 vehicles from circulation.
- 2,690 GJ/year in thermal energy savings (equal to 747 MWh).
- USD 10M annual economic savings associated with lower energy consumption.
These improvements position ME Elecmetal Funvesa as one of the most efficient operations in the country in its category and make it a benchmark for the Peruvian industrial ecosystem.
Regarding qualitative productive and operational impacts, highlights include:
- Greater capacity for large parts, expanding the available portfolio for mining clients.
- Safer and more mechanized process, reducing physical load and risks for operators.
- Greater consistency in mechanical properties, directly impacting the service life and performance of components.
At the same time, this naturally integrates with the ME FIT value proposition, ME Elecmetal’s wear engineering portfolio that supports its clients with design, simulation, monitoring, and continuous improvement for crushing and grinding.
“This project simplifies processes, reduces energy consumption, and decreases operational risks. It represents working in line with ME Elecmetal’s values”
The modernization of Funvesa responds to ME Elecmetal’s commitment to consolidate a circular business model, where in the case of ME South America, 96% of the steel used per ton of product is recycled and to reduce emission intensity by 52% per ton produced by 2030. Thus, the incorporation of a more efficient heat treatment furnace in Peru integrates into that strategy and strengthens the coherence of the model in the region.
Undoubtedly, the recognition of ME Elecmetal Funvesa as a success case by the ZIS Peru program demonstrates the real contribution heavy industry can make when incorporating innovation, energy efficiency, and a responsible environmental approach.
