Driving down element turnaround time while improving quality and decreasing waste is being achieved at Weir Minerals Africa’s thrilling new Replicast Plant in Isando, Gauteng.
Umar Smith, plant manager at Weir Minerals Africa’s Isando facility, highlights that the innovative development enables the company to provide extra parts at a time – and more shortly. This will help in assembly growing buyer demand, whereas additionally lowering rework and wastage.
“As a part of our Project Vuka, this new plant permits us to forged a quantity of small parts per batch quite than just one at a time,” says Smith. “We can also reduce our knock-out instances from days to just a few hours.”
The state-of-the-art services enable Weir Minerals Africa to forged excessive chrome elements weighing up to 250 kg. There are pressure gauge ไท วัสดุ to the model new course of, he explains, which uses polystyrene to create moulds. The first phase 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 distinction 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 together with the polystyrene mould, he says. The system includes a vacuum bin, from which all the air is eliminated to compress the sand.
“The absence of resin and catalyst – as properly as having no clamping process – leads to much less scrap being produced, and due to this fact brings operational financial savings,” he says. “The high quality of castings can also be raised, with a greater surface finish and fewer defects.”
He notes that the geometrical stability of parts is improved, as there may be less fettling of the completed product thereby lowering dimensional variation between the identical parts. This in flip contributes to the reliability of the tools utilizing these parts. He says the foundry may even realise vital environmental benefits on account of using no chemical substances in the sand.
“This new plant aligns properly with our company sustainability goals, guaranteeing that our processes aren’t only compliant however continuously cut back our environmental influence,” says Smith. “Our new moulding systems ensure that fewer gases are emitted during the casting process, and there are zero emissions of dangerous substances corresponding to benzene.”
The new expertise is also leading to much less frequent disposal of silica sand, and the sand itself is extra environmentally friendly as it incorporates no resin or acid.
“A remarkable aspect of growing this new plant was the truth that it was carried out 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 carried out on time and within price range.”
The plant consists of greater than 16,000 individual components, and makes use of over 1,900 m of cabling, 300 m of water piping and fifty five tons of metal.

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