Driving down part turnaround time while enhancing 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 revolutionary growth allows the corporate to provide extra elements at a time – and extra rapidly. This will help in meeting growing customer demand, whereas additionally lowering rework and wastage.
“As part of our Project Vuka, this new plant permits us to cast a number of small parts per batch somewhat than simply one by one,” says Smith. “We also can cut back our knock-out instances from days to just a couple of hours.”
The state-of-the-art services enable Weir Minerals Africa to cast excessive chrome components weighing up to 250 kg. There are two phases to the new course of, 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. The second section 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 makes use of silica sand of 30-35 AFS grade together 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 much less scrap being produced, and subsequently brings operational financial savings,” he says. “The high quality of castings can be raised, with a greater surface end and fewer defects.”
He notes that the geometrical stability of components is improved, as there’s much less fettling of the completed product thereby lowering dimensional variation between the identical parts. pressure gauge trerice ราคา in turn contributes to the reliability of the equipment using those parts. He says the foundry may also realise important environmental benefits because of using no chemical compounds within the sand.
“This new plant aligns well with our corporate sustainability targets, making certain that our processes usually are not solely compliant but constantly cut back our environmental impression,” says Smith. “Our new moulding methods be sure that fewer gases are emitted through the casting course of, and there are zero emissions of dangerous substances corresponding to benzene.”
The new expertise can be leading to less frequent disposal of silica sand, and the sand itself is more environmentally pleasant as it incorporates no resin or acid.
“A outstanding facet of developing this new plant was the fact that it was accomplished with our native abilities and largely in the course of 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 within finances.”
The plant consists of greater than sixteen,000 particular person components, and uses over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.

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