Driving down part turnaround time while improving high 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 improvement enables the corporate to produce more elements at a time – and extra rapidly. This will help in meeting growing customer demand, while also decreasing rework and wastage.
“As ที่วัดแรงดัน of our Project Vuka, this new plant allows us to solid multiple small parts per batch somewhat than just one at a time,” says Smith. “We can also reduce our knock-out times from days to simply a few hours.”
The state-of-the-art services enable Weir Minerals Africa to solid high chrome parts 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 section is the polystyrene moulding course of, which occurs after the polystyrene beads have been expanded. The second part is where the ramming, pouring and demoulding takes place.
In distinction to the traditional 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 involves a vacuum bin, from which all the air is removed to compress the sand.
“The absence of resin and catalyst – in addition to having no clamping process – leads to less scrap being produced, and due to this fact brings operational financial savings,” he says. “ เพรสเชอร์เกจดิจิตอล of castings can be raised, with a greater surface finish and fewer defects.”
He notes that the geometrical stability of parts is improved, as there is much less fettling of the completed product thereby reducing dimensional variation between the identical components. This in turn contributes to the reliability of the gear utilizing these elements. He says the foundry may even realise important environmental advantages as a outcome of utilizing no chemicals within the sand.
“This new plant aligns well with our corporate sustainability goals, making certain that our processes usually are not solely compliant but repeatedly cut back our environmental influence,” says Smith. “Our new moulding systems make sure that fewer gases are emitted through the casting process, and there are zero emissions of harmful substances similar to benzene.”
The new expertise is also leading to much less frequent disposal of silica sand, and the sand itself is extra environmentally friendly because it contains no resin or acid.
“A outstanding side of creating 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 expertise, and the logistical challenges created by the pandemic, it was successfully implemented on time and within price range.”
The plant consists of more than sixteen,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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