Driving down element turnaround time whereas bettering quality and reducing 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 growth enables the company to provide extra components at a time – and more rapidly. เครื่องมือวัดความดันคือ will help in meeting rising customer demand, while also reducing rework and wastage.
“As a half of our Project Vuka, this new plant allows us to cast multiple small elements per batch rather than simply one by one,” says Smith. “We can also cut back our knock-out times from days to only a few hours.”
The state-of-the-art services enable Weir Minerals Africa to forged excessive chrome elements weighing as a lot as 250 kg. There are เกจวัดแรงดันลมราคา to the brand new process, he explains, which makes use of polystyrene to create moulds. The first part 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 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 much less scrap being produced, and therefore brings operational savings,” he says. “The high quality of castings can be raised, with a better floor finish and fewer defects.”
He notes that the geometrical stability of elements is improved, as there may be less fettling of the completed product thereby decreasing dimensional variation between the same parts. This in turn contributes to the reliability of the tools using those components. He says the foundry will also realise vital environmental benefits on account of utilizing no chemicals within the sand.
“This new plant aligns properly with our company sustainability objectives, ensuring that our processes usually are not only compliant however continuously scale back our environmental influence,” says Smith. “Our new moulding techniques ensure that fewer gases are emitted in the course of the casting course of, and there are zero emissions of dangerous substances corresponding to benzene.”
The new technology can also be resulting in less frequent disposal of silica sand, and the sand itself is extra environmentally friendly as it incorporates no resin or acid.
“A outstanding facet of developing this new plant was the reality that it was done 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 successfully implemented on time and within finances.”
The plant consists of greater than 16,000 particular person components, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.

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