Smelting & Refining Operations

Operators across much of the smelting industry were adversely affected by the recent disruption to world financial markets.  Dramatic changes in demand from many of the traditional sectors such as automotive and construction for alumina for example caused significant volatility within the market with some companies slow to reduce operations and adjust production as market conditions shifted.

Given the rising cost of energy, energy flexibility is the agenda topping issue for executives alongside sustainability, community engagement, leadership and operational excellence.

We have a dedicated team of energy experts who address energy efficiency.  Applying energy principles to the day-to-day operations of a business help stop the drain from increasing energy costs.

Working with our client’s people, we help realize improvements that, working alone, would take the company significantly longer to deliver.  In challenging times, we provide a welcome buffer to deteriorating market conditions.  Our approach to achieving behavioral change has the added benefit for our clients of creating a culture of continuous improvement.  

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Our Results

 

Clients have seen substantial increases in throughput, and reductions in energy and other costs at all stages of processing through to smelting and refining.

Although the scope for improvement varies between operations, most clients see very significant throughput increases, improved equipment availability and reduced direct costs per ton.  Our clients typically show returns of over 3:1 on their investment. 

 
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Testimonials

 

BHP Billiton Aluminum SA completed two improvement initiatives in strong co-operation with Proudfoot.  Both projects delivered substantial bottom line results.  Aluminium is not immune to the downturn and these two initiatives place us in a better position to manage through these challenging times.

Success in both these initiatives was enabled by great teamwork and the quality of the team, members from within as well as from Proudfoot.  The methodology, discipline, experiences, drive and momentum Proudfoot brings to the table are some of the key ingredients for success.  It was a real pleasure and privilege working with them as partners in delivering ongoing improvement.
Chief Operating Officer, BHP Aluminum Southern Africa




Our plant is now performing at its best levels ever in its 38 year history. We may have been able to have achieved some of the improvements on our own, but all would agree that Proudfoot has definitely added value and helped us move faster on all improvements. All in all, one of the best investments we have ever made.
Kaiser VALCO





I’d heard of Proudfoot from my mining days in Canada but my perception of them had been that they were focused purely on head-count reduction.  So their initial recommendation was a little surprising in that its aim was to improve overall output with no head-count reduction. The results speak for themselves: we have achieved record production levels successively for the last three years. Their ‘toolkit’ for on-the-floor execution is excellent; it’s really a manual for how to change a culture for higher performance and then make it stick. Their people are good leaders with the tools, discipline and experience to make effectiveness in execution routine in the workforce.
President, Manitoba Operations, Vale-Inco 
 


Zincor is now a world class company!  With Proudfoot’s assistance, our cost per ton is comparable with the lowest in the world, our productivity has improved by over 30%, and our profits have doubled.  I highly recommend Proudfoot as a business partner.
General Manager, Zinc Corporation of South Africa 



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Case Studies

Energy Efficiency - Powering up the workforce to conserve energy  Read more >> 

The Commodity of Excellence - Aluminum smelter and fabricator partners with Proudfoot to maintain competitive edge  Read more >> 

A large Colombian mining operation experiences significant productivity improvement by focusing on improving supervisor behaviors  Read more >>