Driving down part turnaround time whereas improving quality and decreasing 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 progressive improvement allows the corporate to produce extra components at a time – and extra shortly. This will help in meeting rising customer demand, while also decreasing rework and wastage.
“As part of our Project Vuka, this new plant permits us to solid a quantity of small elements per batch somewhat than just one at a time,” says Smith. “We can even reduce our knock-out instances from days to only a few hours.”
The state-of-the-art amenities enable Weir Minerals Africa to solid excessive chrome components weighing up to 250 kg. There are two phases to the brand new process, he explains, which makes use of 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 the place 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 together 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 nicely as having no clamping process – ends in less scrap being produced, and due to this fact brings operational financial savings,” he says. “The quality of castings can additionally be raised, with a better surface finish and fewer defects.”
He notes that the geometrical stability of components is improved, as there’s less fettling of the finished product thereby decreasing dimensional variation between the identical parts. เกรดวัดแรงดัน in turn contributes to the reliability of the gear using these elements. He says the foundry may also realise vital environmental advantages on account of using no chemical substances within the sand.
“This new plant aligns well with our corporate sustainability goals, ensuring that our processes usually are not solely compliant however repeatedly scale back our environmental impression,” says Smith. “Our new moulding methods make positive that fewer gases are emitted during the casting course of, and there are zero emissions of harmful substances corresponding to benzene.”
The new know-how can additionally be leading to less frequent disposal of silica sand, and the sand itself is extra environmentally friendly as it contains no resin or acid.
“A outstanding side of developing this new plant was the fact that it was done with our native skills and largely during 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 greater than 16,000 particular person parts, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.

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