Driving down element turnaround time while bettering high quality and decreasing waste is being achieved at Weir Minerals Africa’s exciting new Replicast Plant in Isando, Gauteng.
Umar Smith, plant manager at Weir Minerals Africa’s Isando facility, highlights that the progressive development allows the company to supply extra elements at a time – and extra rapidly. This will help in assembly rising buyer demand, whereas additionally lowering rework and wastage.
“As part of our Project Vuka, this new plant allows us to forged multiple small parts per batch rather than simply one at a time,” says Smith. “We can also cut back our knock-out instances from days to simply a couple of hours.”
The state-of-the-art services enable Weir Minerals Africa to cast excessive chrome elements weighing up to 250 kg. There are two phases to the new process, he explains, which makes use of 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 standard 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 includes a vacuum bin, from which all of the air is removed to compress the sand.
“The absence of resin and catalyst – in addition to having no clamping course of – leads to much less scrap being produced, and subsequently brings operational financial savings,” he says. “The high quality of castings can be raised, with a better surface finish and fewer defects.”
He notes that the geometrical stability of components is improved, as there is less fettling of the completed product thereby lowering dimensional variation between the same elements. This in flip contributes to the reliability of the gear utilizing those parts. He says the foundry will also realise significant environmental benefits on account of using no chemical substances in the sand.
“This new plant aligns nicely with our corporate sustainability goals, ensuring that our processes aren’t solely compliant but repeatedly cut back our environmental influence,” says Smith. “Our new moulding techniques make sure that fewer gases are emitted during the casting process, and there are zero emissions of dangerous substances similar to benzene.”
The new expertise can also be resulting in much less frequent disposal of silica sand, and the sand itself is extra environmentally pleasant because it incorporates no resin or acid.
pressure gauge แบบ น้ำมัน of growing this new plant was the truth that it was carried out with our native expertise and largely through 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 inside finances.”
The plant contains more than 16,000 particular person parts, and makes use of over 1,900 m of cabling, 300 m of water piping and fifty five tons of steel.

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