How One Expanded Mesh Machine Setup Doubled Output for a Wire Products Factory in Peru
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Add time:2025-05-28 09:37
In the heart of Peru’s bustling manufacturing sector, a family-owned wire products factory faced a critical challenge: surging demand for construction and agricultural mesh had outpaced their decades-old manual machinery. With orders piling up and competitors gaining ground, the factory turned to automation. Their solution? A DAPU expanded metal mesh machine. Here’s how this single investment transformed their operations, doubled output, and positioned them as a regional leader.
The Problem: Stagnant Growth in a Booming Market
For years, Lima Wireworks (name changed) relied on manual labor and semi-automatic machines to produce expanded metal mesh for Peru’s construction and farming sectors. But by 2022, their limitations became glaring:
Slow Production: 15 workers produced just 800m² of mesh daily.
High Waste: 25% material loss due to imprecise cutting.
Energy Costs: Aging machines consumed 35kW/hour, straining their budget amid Peru’s rising electricity rates.
Quality Issues: Inconsistent diamond patterns led to rejected shipments from mining clients.
“We were losing contracts to Chilean imports,” recalls plant manager Carlos Rojas. “We needed a machine that could match our ambitions.”
The Solution: Why Lima Wireworks Chose DAPU
After evaluating brands from China, Germany, and the U.S., Lima Wireworks selected DAPU’s 63T Expanded Metal Machine for three reasons:
1. Precision Meets Speed
Key Specs:
Punch Speed: 75 RPM
Material Thickness: 0.5–3mm
Max Width: 2000mm
Impact:
The 63T’s servo-driven blades cut and stretch steel sheets with ±0.3mm accuracy, eliminating pattern inconsistencies.
2. Energy Efficiency
Key Specs:
Motor: 15kW (40% less power than their old machine).
Impact:
Reduced hourly energy costs from $4.20 to $2.50 – saving $1,200/month.
3. Space-Smart Design
Key Specs:
Footprint: 2000x3950x2300mm (fits their 150㎡ workshop).
Auto Stacker: Integrated system saved 30% floor space.
The Transformation: Doubling Output in 90 Days
Phase 1: Installation & Training
DAPU’s Lima-based technicians installed the 63T in 5 days, followed by a 3-day training program for 8 operators. Key upgrades included:
PLC Touchscreen: Spanish interface simplified adjustments.
Quick-Change Tooling: Swapped from 3mm fencing mesh to 1mm decorative panels in 12 minutes.
Phase 2: Results
Within three months, Lima Wireworks achieved:
Output Surge: 1,600m²/day (100% increase).
Waste Reduction: 5% scrap rate (from 25%).
Labor Optimization: 8 workers managed production vs. 15 previously.
“Our biggest client, a mining company in Arequipa, doubled their orders after seeing the consistency,” says Rojas.
Behind the Numbers: How DAPU’s 63T Made It Possible
1. Speed Without Sacrifice
75 RPM Punching: Produced 2000mm-wide mesh at 18 meters/hour.
Case Example: A 10-ton steel coil processed in 6 hours (previously 14 hours).
2. Versatility for Diverse Orders
0.5mm Aluminum: Crafted lightweight screens for Lima office buildings.
3mm Galvanized Steel: Durable fencing for Andean farms.
3. Low Maintenance, High Uptime
Auto-Lubrication: Reduced daily maintenance from 2 hours to 20 minutes.
Dust-Resistant Blades: Withstood Peru’s coastal humidity and desert sand.
The Ripple Effect: Beyond Production
The 63T’s impact extended beyond the factory floor:
New Markets: Entered Ecuador’s agricultural sector with 2000mm-wide avocado farm fencing.
Employee Growth: Two operators were promoted to oversee automation workflows.
Sustainability: Recycled scrap metal generated $800/month in额外收入.
Why Peruvian Manufacturers Are Following Suit
Lima Wireworks’ success story reflects a broader trend in Peru:
Cost Savings: DAPU machines offer 30–50% lower TCO (Total Cost of Ownership) vs. European brands.
Local Support: Spanish-speaking technicians and Lima-based spare parts仓库 ensure <48hr response times.
Government Incentives: Peru’s “Industry 4.0” grants cover 15% of automation equipment costs.
Future-Proofing with DAPU
Lima Wireworks plans to add a 160T/A model for 4mm+ mining conveyor belts. “With DAPU, we’re not just surviving – we’re leading,” says Rojas.
Conclusion
For Peruvian manufacturers, automation isn’t a luxury – it’s survival. By investing in DAPU’s 63T expanded metal machine, Lima Wireworks doubled output, slashed costs, and reclaimed its competitive edge. In a region where 72% of factories still rely on manual processes, their story is a blueprint for growth.
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