Driving down part turnaround time while enhancing high quality and decreasing waste is being achieved at Weir Minerals Africa’s exciting new Replicast Plant in Isando, Gauteng.
Umar Smith, plant supervisor at Weir Minerals Africa’s Isando facility, highlights that the revolutionary improvement permits the company to supply more parts at a time – and extra rapidly. This will help in assembly growing customer demand, whereas additionally reducing rework and wastage.
“As a part of our Project Vuka, this new plant allows us to forged a number of small parts per batch somewhat than just separately,” says Smith. “We also can cut back our knock-out times 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 model new course of, he explains, which makes use of polystyrene to create moulds. The first part is the polystyrene moulding process, which occurs after the polystyrene beads have been expanded. The second phase is the place the ramming, pouring and demoulding takes place.
In distinction to the traditional moulding line – where resin and catalyst are used to bind sand – the Replicast Plant makes use of silica sand of 30-35 AFS grade together with the polystyrene mould, he says. The system entails 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 process – leads to much less scrap being produced, and subsequently brings operational 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 is much less fettling of the completed product thereby decreasing dimensional variation between the same parts. This in flip contributes to the reliability of the equipment using those components. He says the foundry may also realise significant environmental advantages on account of utilizing no chemical compounds in the sand.
“This new plant aligns properly with our corporate sustainability objectives, guaranteeing that our processes aren’t solely compliant but continuously cut back our environmental impact,” says Smith. “Our new moulding techniques make positive that fewer gases are emitted through the casting process, and there are zero emissions of dangerous substances similar to benzene.”
The new technology is also leading to much less frequent disposal of silica sand, and the sand itself is more environmentally pleasant because it accommodates no resin or acid.
“A remarkable facet of developing this new plant was the fact that it was accomplished with our local expertise and largely during the COVID-19 lockdowns,” he says. “Despite เกจวัดแรงดันลมดิจิตอล of this technology, and the logistical challenges created by the pandemic, it was efficiently carried out on time and inside budget.”
The plant includes greater than sixteen,000 particular person elements, and uses over 1,900 m of cabling, 300 m of water piping and fifty five tons of steel.

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