Summary
(OEM and system integrator for aluminum melting and casting systems) End Customer: Aluminum manufacturer
Mechanical installation, Electromechanical integration, PLC & HMI commissioning support, Project leadership and field engineering
Overview
A U.S.-based engineering firm responsible for designing and delivering aluminum melting and casting systems was contracted to build a greenfield aluminum foundry in San Luis Potosí, Mexico.
The project included the installation of high-temperature melting furnaces, auxiliary thermal equipment, dust-collection systems, and plant-wide automation architecture designed and fabricated in the United States.
While engineering and fabrication were completed in the U.S., the full installation, electrical integration, controls commissioning, and startup activities were executed on site in Mexico.
Boltronic was engaged as a field technical partner to support these activities. Initially brought in for hands-on installation and commissioning support, the company quickly earned the customer’s trust due to its technical expertise, adaptability, and reliability.
As the project progressed, Boltronic’s scope expanded to include leadership responsibilities across mechanical, electromechanical, and controls disciplines, with up to eight engineers and technicians deployed on site during peak phases of the project.
Key Success Factors
- Multi-disciplinary technical expertise across mechanical, electrical, and controls systems
- Ability to integrate with U.S. engineering teams and local contractors
- Strong on-site troubleshooting and commissioning capabilities
- Adaptability to evolving project scope and leadership needs
- Long-term deployment of experienced engineers ensuring continuity
The Challenge
Heavy Industrial Equipment Installation
Installation of high-tonnage melting furnaces, molten metal handling systems, structural platforms, and thermal equipment required precise rigging, alignment, and sequencing.
Complex Commissioning Requirements
Mechanical systems, electrical infrastructure, PLCs, HMIs, safety circuits, interlocks, and environmental controls needed to be validated and synchronized for safe operation.
Multi-Contractor Coordination
Multiple contractors and engineering teams operated simultaneously, requiring tight coordination to avoid schedule conflicts and rework.
Critical Sequencing Dependencies
Delays in mechanical, electrical, or controls workstreams could significantly impact commissioning and startup timelines.
Boltronic’s Solution
Key contributions included:
- Mechanical installation and alignment of aluminum melting furnaces and thermal systems
- Support for rigging operations, equipment placement, and structural assembly
- Installation of platforms, support structures, and material-handling systems
- PLC and HMI integration, device validation, and commissioning support
- Implementation of testing protocols and troubleshooting during startup
- Coordination between U.S. engineering teams and local contractors
- Daily planning, progress tracking, and issue resolution on site
BOLTRONIC’S
Results and Impact
Client Value