เกจ์อาร์กอนsumo down element turnaround time while bettering high quality and reducing 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 growth enables the company to produce more parts at a time – and extra quickly. This will help in assembly rising buyer demand, while also lowering rework and wastage.
“As a half of our Project Vuka, this new plant allows us to forged multiple small components per batch rather than just one by one,” says Smith. “We can even scale back our knock-out occasions from days to simply a few hours.”
The state-of-the-art facilities enable Weir Minerals Africa to cast high chrome parts weighing up to 250 kg. There are two phases to the new course of, he explains, which uses polystyrene to create moulds. The first section is the polystyrene moulding process, which happens after the polystyrene beads have been expanded. The second phase is the place the ramming, pouring and demoulding takes place.
In distinction to the normal moulding line – where 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 includes a vacuum bin, from which all the air is eliminated to compress the sand.
“The absence of resin and catalyst – in addition to having no clamping course of – results in less scrap being produced, and subsequently brings operational savings,” he says. “The quality of castings can additionally be raised, with a greater floor end and fewer defects.”
He notes that the geometrical stability of parts is improved, as there’s less fettling of the finished product thereby reducing dimensional variation between the identical parts. This in turn contributes to the reliability of the gear utilizing these components. He says the foundry will also realise significant environmental benefits because of using no chemicals in the sand.
“This new plant aligns nicely with our company sustainability goals, making certain that our processes are not solely compliant but constantly reduce our environmental impact,” says Smith. “Our new moulding techniques be sure that fewer gases are emitted through the casting process, and there are zero emissions of dangerous substances similar to benzene.”
The new know-how is also leading to much less frequent disposal of silica sand, and the sand itself is more environmentally pleasant because it incorporates no resin or acid.
“A remarkable side of creating this new plant was the truth that it was carried out with our native skills 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 applied on time and inside finances.”
The plant contains more than sixteen,000 individual parts, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.