Driving down element turnaround time whereas enhancing quality and reducing waste is being achieved at Weir Minerals Africa’s exciting new Replicast Plant in Isando, Gauteng.
ตัววัดแรงดันน้ำ , plant manager at Weir Minerals Africa’s Isando facility, highlights that the progressive improvement allows the corporate to produce extra elements at a time – and more shortly. This will assist in assembly rising buyer demand, while additionally lowering rework and wastage.
“As part of our Project Vuka, this new plant allows us to cast multiple small elements per batch rather than simply separately,” says Smith. “We can even reduce our knock-out instances from days to only a couple of hours.”
The state-of-the-art services enable Weir Minerals Africa to solid high chrome components weighing up to 250 kg. There are two phases to the brand new course of, he explains, which makes use of polystyrene to create moulds. The first section is the polystyrene moulding process, which occurs after the polystyrene beads have been expanded. The second part is where the ramming, pouring and demoulding takes place.
In contrast to the standard moulding line – the place resin and catalyst are used to bind sand – the Replicast Plant makes use of silica sand of 30-35 AFS grade along with the polystyrene mould, he says. The system includes a vacuum bin, from which all of the air is eliminated to compress the sand.
“The absence of resin and catalyst – as nicely as having no clamping course of – leads to less scrap being produced, and subsequently brings operational savings,” he says. “The high quality of castings can also be raised, with a better floor end and fewer defects.”
He notes that the geometrical stability of parts is improved, as there’s less fettling of the completed product thereby decreasing dimensional variation between the same parts. This in flip contributes to the reliability of the gear using those elements. He says the foundry may even realise vital environmental advantages because of utilizing no chemicals within the sand.
“This new plant aligns properly with our corporate sustainability targets, making certain that our processes are not solely compliant but repeatedly reduce our environmental impact,” says Smith. “Our new moulding methods make sure that fewer gases are emitted through the casting course of, and there are zero emissions of harmful substances such as benzene.”
The new expertise can additionally be resulting in much less frequent disposal of silica sand, and the sand itself is more environmentally friendly as it incorporates no resin or acid.
“A remarkable side of creating this new plant was the fact that it was accomplished with our native expertise and largely in the course of the COVID-19 lockdowns,” he says. “Despite the novelty of this know-how, and the logistical challenges created by the pandemic, it was efficiently implemented on time and within price range.”
The plant consists of more than sixteen,000 individual elements, and uses over 1,900 m of cabling, 300 m of water piping and fifty five tons of metal.

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