Driving down element turnaround time whereas enhancing high quality and lowering 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 extra parts at a time – and extra shortly. This will help in meeting rising buyer demand, whereas also decreasing rework and wastage.
“As part of our Project Vuka, this new plant allows us to cast multiple small parts per batch rather than simply one by one,” says Smith. “We can even reduce our knock-out instances from days to simply a couple of hours.”
The state-of-the-art facilities allow Weir Minerals Africa to cast high chrome elements weighing up to 250 kg. There are เกจวัดแรงดันsumo to the model new process, he explains, which uses polystyrene to create moulds. The first section 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 distinction 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 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 – in addition to having no clamping process – ends in much less scrap being produced, and subsequently brings operational financial savings,” he says. “The quality of castings can also be raised, with a better floor end and fewer defects.”
He notes that the geometrical stability of elements is improved, as there’s less fettling of the completed product thereby reducing dimensional variation between the same parts. This in flip contributes to the reliability of the tools utilizing these parts. He says the foundry may also realise significant environmental benefits as a outcome of using no chemical compounds in the sand.
“This new plant aligns well with our company sustainability targets, guaranteeing that our processes are not only compliant but repeatedly reduce our environmental influence,” says Smith. “Our new moulding systems be positive that fewer gases are emitted in the course of the casting process, and there are zero emissions of dangerous substances such as benzene.”
The new know-how is also resulting in much less frequent disposal of silica sand, and the sand itself is extra environmentally pleasant as it incorporates no resin or acid.
“A exceptional facet of creating this new plant was the fact that it was done with our native abilities and largely through the COVID-19 lockdowns,” he says. “Despite the novelty of this expertise, and the logistical challenges created by the pandemic, it was successfully applied on time and within price range.”
The plant consists of more than 16,000 individual components, and uses over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.

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