Driving down part turnaround time while bettering 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 progressive improvement permits the corporate to provide extra elements at a time – and extra rapidly. This will help in meeting rising buyer demand, while also reducing rework and wastage.
“As a part of our Project Vuka, this new plant permits us to solid multiple small elements per batch rather than just separately,” says Smith. “We can even scale back our knock-out occasions from days to just a few hours.”

The state-of-the-art amenities enable Weir Minerals Africa to cast excessive chrome components weighing up to 250 kg. There are two phases to the model new course of, he explains, which uses polystyrene to create moulds. เกจวัดแรงดันน้ำไทวัสดุ is the polystyrene moulding process, which occurs after the polystyrene beads have been expanded. The second phase is the place 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 along 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 – as nicely as having no clamping process – results in less scrap being produced, and subsequently brings operational financial savings,” he says. “The quality of castings can be raised, with a greater floor end and fewer defects.”

He notes that the geometrical stability of components is improved, as there is much less fettling of the finished product thereby lowering dimensional variation between the same elements. This in flip contributes to the reliability of the tools using these parts. He says the foundry may also realise significant environmental advantages because of using no chemicals in the sand.
“This new plant aligns well with our company sustainability objectives, guaranteeing that our processes aren’t solely compliant however repeatedly scale back our environmental impact,” says Smith. “Our new moulding techniques be certain that fewer gases are emitted through the casting process, and there are zero emissions of harmful substances corresponding to benzene.”

The new technology can also be resulting in much less frequent disposal of silica sand, and the sand itself is more environmentally pleasant because it incorporates no resin or acid.
“A outstanding side of developing this new plant was the fact that it was accomplished with our native abilities 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 components, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of metal.

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