Driving down component turnaround time whereas enhancing quality and lowering waste is being achieved at Weir Minerals Africa’s thrilling new Replicast Plant in Isando, Gauteng.
Umar Smith, plant supervisor at Weir Minerals Africa’s Isando facility, highlights that the innovative improvement allows the company to produce more components at a time – and extra rapidly. This will assist in meeting rising customer demand, whereas also reducing rework and wastage.
“As part of our Project Vuka, this new plant permits us to cast a number of small parts per batch somewhat than simply separately,” says Smith. “We also can reduce our knock-out occasions from days to just a few hours.”
The state-of-the-art facilities enable Weir Minerals Africa to solid excessive chrome elements weighing as a lot as 250 kg. There are two phases to the brand new process, he explains, which uses polystyrene to create moulds. The first part is the polystyrene moulding course of, which occurs after the polystyrene beads have been expanded. The second phase is where the ramming, pouring and demoulding takes place.
In contrast to the traditional moulding line – the place resin and catalyst are used to bind sand – the Replicast Plant uses silica sand of 30-35 AFS grade along with the polystyrene mould, he says. The system entails a vacuum bin, from which all the air is eliminated to compress the sand.
“The absence of resin and catalyst – as well as having no clamping process – results in less scrap being produced, and therefore brings operational savings,” he says. “The high quality of castings can be raised, with a better floor finish and fewer defects.”
He notes that the geometrical stability of components is improved, as there’s much less fettling of the completed product thereby reducing dimensional variation between the identical elements. This in turn contributes to the reliability of the equipment utilizing these parts. pressure gauge วัด แรง ดัน น้ำ says the foundry may even realise important environmental benefits because of utilizing no chemical substances in the sand.
“This new plant aligns properly with our company sustainability targets, making certain that our processes usually are not solely compliant however repeatedly cut back our environmental influence,” says Smith. “Our new moulding techniques make positive that fewer gases are emitted during the casting course of, and there are zero emissions of harmful substances such as benzene.”
The new expertise can additionally be resulting in less frequent disposal of silica sand, and the sand itself is extra environmentally pleasant as it contains no resin or acid.
“A outstanding facet of growing this new plant was the reality that it was done with our local abilities and largely through the COVID-19 lockdowns,” he says. “Despite the novelty of this expertise, and the logistical challenges created by the pandemic, it was successfully carried out on time and inside price range.”
The plant includes more than sixteen,000 individual elements, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of metal.

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