Driving down part turnaround time whereas improving high quality and decreasing 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 development permits the corporate to provide more elements at a time – and more rapidly. This will help in meeting rising customer demand, while also decreasing rework and wastage.
“As a half of our Project Vuka, this new plant permits us to cast multiple small components per batch quite than simply one by one,” says Smith. “We also can cut back our knock-out times from days to only a few hours.”
The state-of-the-art facilities allow Weir Minerals Africa to solid excessive chrome parts weighing as much as 250 kg. There are two phases to the new course of, he explains, which makes use of polystyrene to create moulds. The first phase is the polystyrene moulding course of, which happens after the polystyrene beads have been expanded. The second part is where the ramming, pouring and demoulding takes place.
In distinction to the normal 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 entails 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 – results in less scrap being produced, and subsequently brings operational financial savings,” he says. “The quality of castings can also be raised, with a better floor finish and fewer defects.”
He notes that the geometrical stability of elements is improved, as there’s less fettling of the finished product thereby lowering dimensional variation between the identical elements. This in turn contributes to the reliability of the equipment utilizing these parts. เกจวัดแรงดันแก๊สหุงต้ม says the foundry may even realise vital environmental benefits on account of using no chemical substances within the sand.
“This new plant aligns properly with our company sustainability objectives, guaranteeing that our processes aren’t only compliant but repeatedly scale back our environmental impression,” says Smith. “Our new moulding systems be positive that fewer gases are emitted through the casting course of, and there are zero emissions of harmful substances corresponding to benzene.”
The new know-how can also be leading to much less frequent disposal of silica sand, and the sand itself is extra environmentally friendly as it contains no resin or acid.
“A outstanding facet of creating this new plant was the fact that it was carried out with our local skills 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 inside price range.”
The plant contains more than sixteen,000 particular person elements, and makes use of over 1,900 m of cabling, 300 m of water piping and fifty five tons of metal.

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