pressure gauge octa down element turnaround time whereas enhancing quality and reducing 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 development allows the company to provide more components at a time – and extra rapidly. This will assist in assembly growing customer demand, while also decreasing rework and wastage.
“As part of our Project Vuka, this new plant allows us to solid multiple small parts per batch somewhat than simply one at a time,” says Smith. “We can even scale back our knock-out times from days to only a few hours.”

The state-of-the-art services allow Weir Minerals Africa to forged high chrome parts weighing as much as 250 kg. There are pressure gauge to the model new process, he explains, which uses polystyrene to create moulds. The first section is the polystyrene moulding process, which happens after the polystyrene beads have been expanded. The second part is the place the ramming, pouring and demoulding takes place.
In distinction to the normal moulding line – the place resin and catalyst are used to bind sand – the Replicast Plant uses silica sand of 30-35 AFS grade together with the polystyrene mould, he says. The system includes a vacuum bin, from which all the air is eliminated to compress the sand.
“The absence of resin and catalyst – as nicely as having no clamping process – ends in less scrap being produced, and subsequently brings operational savings,” he says. “The high quality of castings can additionally be raised, with a greater surface end and fewer defects.”

He notes that the geometrical stability of parts is improved, as there could be less fettling of the finished product thereby lowering dimensional variation between the same parts. This in turn contributes to the reliability of the equipment utilizing these components. He says the foundry will also realise significant environmental benefits because of utilizing no chemical substances within the sand.
“This new plant aligns well with our company sustainability goals, making certain that our processes aren’t only compliant but continuously reduce our environmental impression,” says Smith. “Our new moulding techniques be certain that fewer gases are emitted through the casting process, and there are zero emissions of dangerous substances similar to benzene.”

The new technology can additionally be resulting in less frequent disposal of silica sand, and the sand itself is extra environmentally friendly as it contains no resin or acid.
“A exceptional aspect of developing this new plant was the reality that it was accomplished with our local expertise and largely during the COVID-19 lockdowns,” he says. “Despite the novelty of this technology, and the logistical challenges created by the pandemic, it was efficiently implemented on time and within budget.”

The plant contains more than sixteen,000 particular person components, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of metal.

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