ME FIT Programs

ME FIT Grinding

We offer integral and technical solutions to help our customers tackle the unique challenges at each mining operation and to positively impact priority KPIs: tons per hour, safety management, availability and maintainability of equipment, risk prevention, among others.

ME FIT Crushing

We design solutions to help our customers achieve their goals by combining crusher wear parts with technology tools, advice, training and monitoring — all of which allow us to create value in our customers’ processes.

Products and Services

Crushing

We provide wear parts for primary, secondary and tertiary crushing applications for the mining, aggregate and recycle industries with optimal designs and alloys specifically developed for each application.

Grinding

We are the world leader in designing and supplying highly engineered grinding mill liners for SAG, AG, ball, tower and rod milling.

Grinding Media

ME Elecmetal designs, manufactures and supplies the highest quality forged steel grinding media for SAG, ball and rod mills in the world.

Digital Solutions

Technology solutions that add value to mining processes for making timely decisions and recommendations to ME Elecmetal's clients.

ME Digital Lab

ME Elecmetal combines technology and innovation to serve the global mining industry with integral solutions to optimize processes.

Aggregate Solutions

Aggregate

We are a crushing and wear solutions innovator born in mining, now leading in aggregate. We combine speed, customization, and quality to help distributors outperform OEMs with smarter, faster, and safer solutions.

In a recent campaign, ME Elecmetal's customized liner solution helped a mining operation process 11.08 million tons, a dramatic increase from the 4.54 million tons achieved with OEM liners in the previous campaign.

The client identified a pressing need to enhance the performance of their primary crusher, which was experiencing frequent unscheduled shutdowns due to excessive thermal loading—resulting in significant losses in operating hours. Compounding the issue was an unpredictable variation in pole height, further complicating operational planning.

Several recurring issues were directly impacting the crusher’s efficiency and reliability:

  • Localized wear on the lower mantle, particularly in the area known as the “ducktail,” leading to profile loss, reduced capacity, and increased exposure to premature failures.
  • Critical thermal increases, with thermal capacity surges exceeding 80%, forcing emergency shutdowns.
  • Variability in pole height, which complicated operational planning and generated uncertainty in equipment performance.

These factors led to a highly unstable operation with inconsistent liner performance, inefficient fines evacuation, and diminished overall ore processing. As a result, plant throughput was limited—failing to exceed seven million tons per campaign and reducing the effective treatment rate.

In response, ME Elecmetal partnered with the client to analyze the wear behavior of the OEM-supplied liners (mantle and concaves) and assess operational conditions. This opened the door to reengineering the system to improve fines evacuation and increase ore throughput (tph).

Through a collaborative and data-driven approach—centered on analysis, diagnostics, and co-design with the client’s operations team—ME Elecmetal developed a comprehensive solution to significantly improve the performance of the primary crusher. The proposal was built on three strategic pillars:

1. Customized Mantle Design with Conical Profile
ME Elecmetal reengineered the lower mantle, introducing an optimized conical profile designed to:

  • Improve the flow of fine material evacuation.
  • Reduce mineral accumulation in the crushing chamber.
  • Decrease excessive contact points that accelerated wear.

This redesign aimed to improve overall crushing efficiency by lowering internal pressure and increasing the equipment’s effective processing capacity.

2. Optimized Alloy Selection – M3 (18% Mn)
Given the abrasive characteristics of the processed ore, ME Elecmetal selected its M3 alloy, composed of 18% manganese, offering superior resistance to impact and friction. The benefits of this alloy include:

  • Extended wear life of critical crusher components.
  • Reduced wear rate per ton of processed material.
  • Sustained operational geometry, contributing to consistent performance over time.

3. Wear Monitoring with QuickScan Crusher Technology
To ensure continuous performance tracking, ME Elecmetal implemented its QuickScan Crusher 3D scanning technology. This system provides high-resolution wear data on mantles, concaves, and pole height variation—enabling:

  • Timely and informed decisions on component replacement.
  • Predictive insights into future liner behavior and equipment performance.

Together, these enhancements laid the foundation for a more efficient, stable, and predictable crushing operation—delivering measurable improvements in both productivity and equipment reliability.

Benefits

Reliable Performance

Continuous, predictable performance without unplanned failures.

Increased Productivity

More ore processed with fewer resources, including reduced time, labor, and energy.

Reduced Carbon Footprint

Fewer replacements per campaign means less steel production, transportation, energy use, and waste—significantly reducing environmental impact.

Enhanced Safety

Reduced maintenance frequency lowers worker exposure to high-risk tasks.

“This success story isn’t simply about changing liners; it represents the materialization of ME Elecmetal’s comprehensive offering, based on a differentiated value proposition. This proposition considers elements such as: advanced diagnosis and customization, innovation in design and materials, continuous monitoring, control and technical support, and a long-term strategic relationship with the client.“

— Javier Cabezas, Wear Parts Category Manager de ME Elecmetal

 Javier Cabezas, Wear Parts Category Manager de ME Elecmetal

Results

ME Elecmetal’s solution delivered transformative results, significantly improving the primary crusher’s performance across multiple dimensions:

1. Substantial Increase in Liner Lifespan

  • Mantles: Average service life increased from 3 to 8 months, resulting in reduced maintenance frequency, lower change-out risks, and improved operational availability.
  • Concaves: Durability extended from 6 to 13 months, effectively doubling performance and further decreasing downtime and maintenance costs.

2. Major Reduction in Unscheduled Downtime Due to Thermal Overload
Historical thermal surges exceeding 80% were brought down to a stable 17%, enabling:

  • Elimination of shutdowns caused by overheating.
  • Improved equipment reliability and continuous operation.
  • Enhanced protection of critical crusher components.

3. Significant Increase in Tonnage Processed per Campaign
Production rose to 11.08 million tons per campaign, nearly doubling the 4.54 million tons achieved with the previous OEM liner setup—representing a substantial boost in processing efficiency and throughput.

Solutions

ME FIT Programs

Products and Services

Aggregate Solutions

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