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 supervisor at Weir Minerals Africa’s Isando facility, highlights that the progressive improvement allows the corporate to produce more parts at a time – and more quickly. This will assist in meeting rising buyer demand, while also decreasing rework and wastage.
“As a part of our Project Vuka, this new plant allows us to solid multiple small parts per batch somewhat than just separately,” says Smith. “We can also scale back our knock-out instances from days to simply a few hours.”
The state-of-the-art services allow Weir Minerals Africa to solid excessive chrome components weighing up to 250 kg. There are two phases to the new process, he explains, which uses polystyrene to create moulds. The first phase is the polystyrene moulding process, which occurs after the polystyrene beads have been expanded. เกจวัดแรงดันลมคือ 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 entails a vacuum bin, from which all of the air is removed to compress the sand.
“The absence of resin and catalyst – as properly as having no clamping process – ends in less scrap being produced, and due to this fact brings operational savings,” he says. “The quality of castings can be raised, with a better surface finish and fewer defects.”
เกจวัดแรงดันถังลม notes that the geometrical stability of components is improved, as there is much less fettling of the completed product thereby reducing dimensional variation between the same parts. This in turn contributes to the reliability of the gear using those parts. He says the foundry may also realise vital environmental advantages on account of using no chemical substances in the sand.
“This new plant aligns properly with our company sustainability objectives, making certain that our processes usually are not only compliant however constantly reduce our environmental impact,” says Smith. “Our new moulding systems be certain that fewer gases are emitted in the course of the casting course of, and there are zero emissions of harmful substances corresponding to benzene.”
The new technology can be resulting in much less frequent disposal of silica sand, and the sand itself is extra environmentally pleasant as it accommodates no resin or acid.
“A remarkable aspect of growing this new plant was the reality that it was done with our native abilities and largely during 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 inside finances.”
The plant consists of more than 16,000 particular person elements, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.

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