Driving down part turnaround time whereas enhancing high 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 innovative growth permits the corporate to provide extra parts at a time – and more quickly. This will assist in meeting growing buyer demand, while additionally lowering rework and wastage.
“As part of our Project Vuka, this new plant permits us to solid multiple small elements per batch rather than just one at a time,” says Smith. “We also can reduce our knock-out instances from days to just a couple of hours.”
The state-of-the-art amenities enable Weir Minerals Africa to solid high chrome components weighing as much as 250 kg. There are two phases to the brand new process, he explains, which uses polystyrene to create moulds. The first part is the polystyrene moulding process, which occurs after the polystyrene beads have been expanded. The second section is the place the ramming, pouring and demoulding takes place.
In Secrets to the traditional moulding line – the place 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 includes a vacuum bin, from which all the air is eliminated to compress the sand.
“The absence of resin and catalyst – in addition to having no clamping course of – leads to much less scrap being produced, and subsequently brings operational savings,” he says. “The quality of castings can additionally be raised, with a better surface finish and fewer defects.”
He notes that the geometrical stability of components is improved, as there may be much less fettling of the completed product thereby lowering dimensional variation between the identical parts. This in flip contributes to the reliability of the equipment utilizing these components. He says the foundry may also realise vital environmental benefits because of utilizing no chemicals within the sand.
“This new plant aligns nicely with our corporate sustainability goals, guaranteeing that our processes usually are not solely compliant but constantly scale back our environmental impression,” says Smith. “Our new moulding systems be certain that fewer gases are emitted through the casting course of, and there are zero emissions of dangerous substances similar to benzene.”
The new know-how is also leading to much less frequent disposal of silica sand, and the sand itself is extra environmentally pleasant because it incorporates no resin or acid.
“A outstanding facet of creating this new plant was the reality that it was accomplished with our native abilities 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 applied on time and within price range.”
The plant consists of 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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