Driving down component turnaround time while bettering quality and lowering waste is being achieved at Weir Minerals Africa’s thrilling new Replicast Plant in Isando, Gauteng.
Umar Smith, plant supervisor at Weir Minerals Africa’s Isando facility, highlights that the progressive development permits the corporate to supply extra elements at a time – and more quickly. This will assist in meeting rising customer demand, whereas additionally decreasing rework and wastage.
“As part of our Project Vuka, this new plant allows us to cast a number of small elements per batch quite than simply separately,” says Smith. “We can also cut back our knock-out occasions from days to just a few hours.”

The state-of-the-art facilities allow Weir Minerals Africa to forged excessive chrome elements weighing as much as 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 process, which occurs after the polystyrene beads have been expanded. The second part is the place the ramming, pouring and demoulding takes place.
In contrast 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 includes a vacuum bin, from which all of the air is removed to compress the sand.
“The absence of resin and catalyst – in addition to having no clamping course of – leads to less scrap being produced, and subsequently brings operational financial savings,” he says. “The high quality of castings can additionally be raised, with a better surface end and fewer defects.”

He notes that the geometrical stability of elements is improved, as there may be much less fettling of the completed product thereby decreasing dimensional variation between the identical elements. This in turn contributes to the reliability of the equipment utilizing those components. digital pressure gauge says the foundry may also realise significant environmental benefits because of utilizing no chemicals in the sand.
“This new plant aligns properly with our company sustainability targets, making certain that our processes are not solely compliant however constantly reduce our environmental influence,” says Smith. “Our new moulding methods make sure that fewer gases are emitted through the casting process, and there are zero emissions of dangerous substances such as benzene.”

The new expertise can also be leading to less frequent disposal of silica sand, and the sand itself is more environmentally pleasant because it accommodates no resin or acid.
“A exceptional facet of growing this new plant was the reality that it was accomplished with our local expertise and largely in the course of 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 finances.”

เพรสเชอร์เกจ includes more than sixteen,000 particular person elements, and uses over 1,900 m of cabling, 300 m of water piping and 55 tons of metal.

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