“In terms of investment, our focus is on strengthening GHI Smart Furnaces' position as a leader in providing advanced turnkey solutions for the aluminium recycling sector,” José Domingo Berasategui, CEO of GHI Smart Furnaces
We are honored to have a conversation with José Domingo Berasategui, CEO of GHI Smart Furnaces. After serving for over a decade as General Manager, Berasategui now takes on the role of executive leader, strengthening GHI’s commitment to innovation and excellence. In an exclusive discussion with AL Circle, he shares insights into his new role and responsibilities, his vision for the future of GHI Furnaces, and his strategy for advancing digitalisation. Most importantly, he highlights his mission to embed a culture of innovation and sustainability at GHI, driving transformation from within.
AL Circle: Congratulations on your appointment as CEO of GHI Smart Furnaces! Please share your vision for the company's future in terms of investment, innovation, and business operations.
José Domingo Berasategui: Thank you! It's an exciting time for GHI Smart Furnaces, and I’m honoured to take on this new role.
In terms of investment, our focus is on strengthening GHI Smart Furnaces' position as a leader in providing advanced turnkey solutions for the aluminium recycling sector. Our strategy also includes expanding our global presence to ensure we are not just a technology leader, but also accessible to new markets that demand high-performance recycling solutions.
Regarding innovation, we are committed to driving significant progress through Smart Process Improvement (SPI) and the digitalisation of our equipment. By integrating data-driven insights and advanced automation, we are optimizing furnace performance and energy efficiency. Digitalisation will empower us with real-time monitoring, predictive maintenance, and smarter decision-making, leading to improved operational outcomes for our customers in the aluminium recycling industry.
When it comes to business operations, I’m committed to fostering a culture of continuous improvement. We will further integrate lean manufacturing practices to eliminate inefficiencies and optimise every aspect of our production. This means refining processes to ensure that we deliver top-quality products while maximising efficiency at every step.
AL Circle: As CEO of GHI, which is the one thing you would like to improve in the first place?
José Domingo Berasategui: As CEO, the first area I’d like to focus on is enhancing our innovation pipeline. While we already deliver advanced furnace solutions, there’s always room to expand, especially in energy efficiency and sustainability. A more structured approach to identifying emerging trends and technologies will ensure we stay ahead of the growing demand for sustainable aluminium recycling.
Additionally, I’d like to enhance our employee development programmes to ensure that every team member has the tools and knowledge to contribute to these innovations. By empowering our engineers, operational teams, and leaders with continuous learning and growth opportunities, we can ensure that GHI Smart Furnaces not only stays ahead in terms of technology but is also a leader in fostering a culture of innovation and sustainability from the inside out.
Image source: GHI Smart Furnaces
AL Circle: Given that GHI is known for advocating smart manufacturing of aluminium products, would you like to increase the use of digitalisation in your furnaces and tailor-made plants? How do you see the future of digitalisation in aluminium production?
José Domingo Berasategui: Absolutely. At GHI Smart Furnaces, we believe that digitalisation is key to the future of aluminium production. We are already leading the way with our integration of Smart Process Improvement (SPI) and data-driven solutions in our furnaces and turnkey plants. By leveraging real-time monitoring and AI-driven insights, we enable our customers to optimise their operations and enhance energy efficiency.
Automation of key processes such as charge preparation, melting, and casting reduces human error, improves consistency, and enhances operator safety. Additionally, the integration of our BeyondAlea platform allows operators to monitor and adjust performance remotely, ensuring better operational outcomes with minimal disruptions.
AL Circle: Amid the ongoing geopolitical and trade tensions worldwide, how do you foresee the investment sentiment for new plants and furnaces among aluminium producers?
José Domingo Berasategui: The ongoing geopolitical and trade tensions certainly present challenges for many industries, including aluminium production. However, I believe that the demand for sustainable aluminium and the ongoing push for circular economies will continue to drive investment in new plants and furnaces, particularly as aluminium producers look to modernise their operations and improve efficiency.
AL Circle: How would you like to enhance the contribution of GHI Smart Furnaces to environmental protection? How do your furnaces and plants help aluminium producers lessen carbon emissions from their operations?
José Domingo Berasategui: At GHI Smart Furnaces, environmental protection is a core focus. We enhance sustainability by designing energy-efficient furnaces, including electrical furnaces for holding and heat treatment, that help reduce carbon emissions in aluminium production. Our advanced recycling solutions allow producers to lower their carbon footprint while meeting growing demand, as recycling uses less energy than primary production.
Additionally, digitalisation plays a key role. With real-time data monitoring and smart process optimisation, we help aluminium producers minimise waste, improve efficiency, and reduce emissions. By integrating predictive maintenance, we also extend the lifespan of our equipment, further supporting environmental goals.
We are also investing in R&D for hydrogen and plasma technology, exploring its potential to reduce emissions even further in aluminium production. Our commitment to energy efficiency and sustainable innovation continues to drive the industry forward toward a greener future.
AL Circle: What is the one product of GHI Smart Furnaces you think needs more awareness among aluminium producers? Would you like to brief us on it?
José Domingo Berasategui: One product that I believe deserves more awareness is our Tilting Rotary Furnace. This furnace stands out due to its exceptional flexibility, being capable of melting a wide variety of scrap and dross, including everything from dirty scrap and foundry returns to automotive parts and aluminium cans. This flexibility is especially important in today’s scrap market, where difficulties in sourcing high-quality or consistent scrap are a constant challenge. Producers never know what type or quality of scrap they’ll have access to, making the versatility of this furnace critical for maintaining productivity and material recovery.
Fully digitalised with advanced AI and sensor technologies, it ensures precise control, high-quality aluminium production, and minimal waste. BeyondAlea integration allows operators to remotely monitor and manage furnace performance, optimising efficiency and ensuring consistent results, regardless of the scrap type.
What truly sets the Tilting Rotary Furnace apart is its ability to handle various scrap types while maintaining high melting efficiency, making it a highly versatile and cost-effective solution for modern aluminium recycling operations.
AL Circle: How extensive is the use of Industry 4.0 in your plants to enable aluminium producers to automate their operations and determine downtime with predictive analytics?
José Domingo Berasategui: At GHI Smart Furnaces, we have fully integrated Industry 4.0 technologies across our operations to help aluminium producers automate processes and proactively manage maintenance. Our furnaces are equipped with real-time monitoring, predictive analytics, and AI-driven process control, which allow for continuous optimisation of the melting and recycling processes.
The use of advanced sensors and data-driven insights enables operators to monitor performance remotely through our BeyondAlea platform, which helps identify potential issues before they lead to downtime. This predictive capability not only improves efficiency and precision but also enables producers to schedule maintenance proactively, reducing unplanned disruptions and extending equipment lifespan. By automating key processes and minimising unexpected downtime, Industry 4.0 helps aluminium producers achieve a more cost-effective and sustainable operation.
AL Circle: Before we end our conversation, please share your 2025 goals in GHI Smart Furnaces.
José Domingo Berasategui: Looking toward the year ahead in 2025, GHI Smart Furnaces aims to strengthen our leadership in the aluminium industry through reliability, sustainability, and technological advancement. We will continue improving our furnace solutions to enhance efficiency and support our customers in reducing energy consumption and carbon emissions.
We will also expand our focus on customised solutions to better meet the diverse needs of aluminium producers, ensuring flexibility and performance for both large-scale and specialised operations.
Investing in our people remains a priority. We are committed to attracting top talent and fostering a culture of continuous improvement to ensure long-term success and innovation.
By the end of 2025, GHI Smart Furnaces will be known for our sustainable solutions, advanced technologies, and strong customer relationships, driving growth and excellence in the industry.
