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 manager at Weir Minerals Africa’s Isando facility, highlights that the progressive improvement allows the corporate to supply extra elements at a time – and extra rapidly. This will assist in meeting growing customer demand, while also reducing rework and wastage.
“As part of our Project Vuka, this new plant allows us to cast a quantity of small parts per batch rather than simply one by one,” says Smith. “We can even scale back our knock-out times from days to just a few hours.”

The state-of-the-art amenities allow Weir Minerals Africa to forged high chrome elements weighing up to 250 kg. There are two phases to the model new course of, he explains, which uses polystyrene to create moulds. The first section is the polystyrene moulding process, which occurs after the polystyrene beads have been expanded. ราคาเกจวัดแรงดันลม is where 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 uses silica sand of 30-35 AFS grade along with the polystyrene mould, he says. The system entails 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 – ends in much less scrap being produced, and due to this fact brings operational savings,” he says. “The quality of castings is also raised, with a greater floor end and fewer defects.”

He notes that the geometrical stability of elements is improved, as there is less fettling of the completed product thereby lowering dimensional variation between the same components. This in turn contributes to the reliability of the equipment using those components. He says the foundry will also realise important environmental advantages as a end result of using no chemicals in the sand.
“This new plant aligns properly with our corporate sustainability objectives, guaranteeing that our processes are not only compliant however continuously cut back our environmental influence,” says Smith. “Our new moulding methods ensure that fewer gases are emitted in the course of the casting process, and there are zero emissions of dangerous substances corresponding to benzene.”

The new know-how is also resulting in less frequent disposal of silica sand, and the sand itself is extra environmentally friendly because it accommodates no resin or acid.
“A outstanding facet of creating this new plant was the fact that it was carried out with our local expertise 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 price range.”

The plant consists of greater than 16,000 particular person parts, and uses over 1,900 m of cabling, 300 m of water piping and 55 tons of metal.

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