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Driving down part turnaround time while bettering high quality and decreasing waste is being achieved at Weir Minerals Africa’s exciting new Replicast Plant in Isando, Gauteng.
Umar Smith, plant manager at Weir Minerals Africa’s Isando facility, highlights that the revolutionary improvement allows the company to produce extra parts at a time – and extra quickly. This will help in meeting growing buyer demand, whereas additionally reducing rework and wastage.
“As a part of our Project Vuka, this new plant permits us to cast a quantity of small components per batch quite than simply separately,” says Smith. “We can even scale back our knock-out instances from days to only a few hours.”

ไดอะแฟรม -of-the-art facilities enable Weir Minerals Africa to cast excessive 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 phase is the polystyrene moulding course of, which happens after the polystyrene beads have been expanded. The second phase 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 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 – as well as having no clamping process – results in less scrap being produced, and subsequently brings operational savings,” he says. “The quality of castings can also be raised, with a greater surface end and fewer defects.”

He notes that the geometrical stability of parts is improved, as there could be much less fettling of the finished product thereby decreasing dimensional variation between the same components. digital pressure gauge in flip contributes to the reliability of the tools using those elements. He says the foundry will also realise important environmental benefits because of utilizing no chemical substances within the sand.
“This new plant aligns nicely with our company sustainability goals, ensuring that our processes usually are not solely compliant but continuously reduce our environmental influence,” says Smith. “Our new moulding techniques make certain that fewer gases are emitted in the course of the casting process, and there are zero emissions of dangerous substances similar to benzene.”

The new know-how can be leading to much less frequent disposal of silica sand, and the sand itself is more environmentally pleasant because it contains no resin or acid.
“A exceptional side of growing this new plant was the truth that it was accomplished with our native 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 carried out on time and within budget.”

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