Driving down part turnaround time whereas improving 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 improvement permits the corporate to produce more elements at a time – and more rapidly. This will assist in assembly rising customer demand, while additionally decreasing rework and wastage.
“As a half of our Project Vuka, this new plant allows us to forged a number of small elements per batch somewhat than just one by one,” says Smith. “We also can cut back our knock-out times from days to simply a couple of hours.”
The state-of-the-art services allow Weir Minerals Africa to solid excessive chrome parts 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 part is the polystyrene moulding course of, which occurs after the polystyrene beads have been expanded. The second section is the place the ramming, pouring and demoulding takes place.
In contrast to the normal moulding line – where 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 involves 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 – results in less scrap being produced, and due to this fact brings operational financial savings,” he says. “The high quality of castings can be raised, with a better surface end and fewer defects.”
He notes that the geometrical stability of elements is improved, as there’s less fettling of the completed product thereby lowering dimensional variation between the identical parts. This in flip contributes to the reliability of the equipment utilizing those parts. He says the foundry may even realise important environmental benefits because of utilizing no chemicals in the sand.
“This new plant aligns properly with our corporate sustainability objectives, ensuring that our processes usually are not only compliant but repeatedly scale back our environmental impact,” says Smith. “ เกจวัดถังแก๊ส ensure that fewer gases are emitted in the course of the casting process, and there are zero emissions of harmful substances such as benzene.”
The new know-how can 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 remarkable aspect of creating this new plant was the reality that it was carried out with our local 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 successfully implemented on time and within budget.”
The plant contains more than sixteen,000 particular person elements, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of metal.

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