Driving down component turnaround time while bettering quality and reducing waste is being achieved at Weir Minerals Africa’s exciting new Replicast Plant in Isando, Gauteng.
เกจวัดแรงดัน4นิ้วราคา , plant supervisor at Weir Minerals Africa’s Isando facility, highlights that the innovative growth permits the company to supply more parts at a time – and more rapidly. This will help in meeting rising customer demand, whereas additionally decreasing rework and wastage.
“As part of our Project Vuka, this new plant allows us to cast multiple small components per batch rather than just one at a time,” says Smith. “We also can cut back our knock-out occasions from days to simply a couple of hours.”
The state-of-the-art facilities allow Weir Minerals Africa to forged high chrome components weighing up to 250 kg. There are two phases to the brand new course of, he explains, which makes use of polystyrene to create moulds. The first part is the polystyrene moulding course of, which occurs 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 together with the polystyrene mould, he says. The system includes a vacuum bin, from which all of the air is eliminated to compress the sand.
“The absence of resin and catalyst – in addition to having no clamping course of – ends in much less scrap being produced, and therefore brings operational financial savings,” he says. “The quality of castings can be raised, with a better surface finish and fewer defects.”
He notes that the geometrical stability of elements is improved, as there is much less fettling of the completed product thereby reducing dimensional variation between the same parts. This in flip contributes to the reliability of the tools using these elements. He says the foundry will also realise significant environmental advantages as a end result of utilizing no chemicals in the sand.
“This new plant aligns nicely with our corporate sustainability objectives, making certain that our processes are not solely compliant however repeatedly reduce our environmental influence,” says Smith. “Our new moulding methods ensure that fewer gases are emitted during the casting process, and there are zero emissions of harmful substances similar to benzene.”
The new know-how can be leading to less frequent disposal of silica sand, and the sand itself is more environmentally friendly as it contains no resin or acid.
“A outstanding facet of growing this new plant was the truth 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 expertise, and the logistical challenges created by the pandemic, it was efficiently carried out on time and inside price range.”
The plant contains more than sixteen,000 individual parts, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of metal.

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