Driving down element turnaround time while improving high quality and lowering waste is being achieved at Weir Minerals Africa’s thrilling new Replicast Plant in Isando, Gauteng.
เพรสเชอร์เกจน้ำ , plant manager at Weir Minerals Africa’s Isando facility, highlights that the progressive growth enables the company to provide more elements at a time – and extra quickly. This will help in meeting growing buyer demand, while additionally decreasing rework and wastage.
“As part of our Project Vuka, this new plant permits us to forged a quantity of small components per batch quite than simply one at a time,” says Smith. “We can also cut back our knock-out times from days to only a couple of hours.”
The state-of-the-art services 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 section is the polystyrene moulding course of, which happens after the polystyrene beads have been expanded. The second section is where the ramming, pouring and demoulding takes place.
In distinction 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 of the air is eliminated 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 financial savings,” he says. “ เครื่องมือที่ใช้วัดความดันโลหิต of castings can be raised, with a better floor end and fewer defects.”
He notes that the geometrical stability of parts is improved, as there is less fettling of the finished product thereby decreasing dimensional variation between the identical parts. This in turn contributes to the reliability of the tools using those components. He says the foundry will also realise vital environmental advantages as a end result of utilizing no chemicals within the sand.
“This new plant aligns well with our company sustainability targets, ensuring that our processes are not only compliant however constantly cut back our environmental impression,” says Smith. “Our new moulding methods 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 know-how can be resulting in less frequent disposal of silica sand, and the sand itself is more environmentally pleasant as it incorporates no resin or acid.
“A outstanding aspect of creating this new plant was the fact that it was done with our local expertise and largely through the COVID-19 lockdowns,” he says. “Despite the novelty of this know-how, and the logistical challenges created by the pandemic, it was efficiently applied on time and inside finances.”
The plant includes more than sixteen,000 individual parts, and uses over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.

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