Driving down part turnaround time whereas improving high quality and reducing waste is being achieved at Weir Minerals Africa’s exciting new Replicast Plant in Isando, Gauteng.
Umar Smith, plant supervisor at Weir Minerals Africa’s Isando facility, highlights that the progressive development permits the company to supply more elements at a time – and extra shortly. This will help in meeting growing customer demand, whereas also decreasing rework and wastage.
“As a half of our Project Vuka, this new plant permits us to solid a number of small elements per batch quite than simply separately,” says Smith. “We can even scale back our knock-out instances from days to simply a few hours.”
The state-of-the-art services enable Weir Minerals Africa to cast high chrome parts weighing as much as 250 kg. There are two phases to the model new process, he explains, which makes use of polystyrene to create moulds. The first part 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 contrast to the standard 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 – in addition to having no clamping process – results in less scrap being produced, and due to this fact brings operational savings,” he says. “The quality of castings can also be raised, with a better surface finish and fewer defects.”
He notes that the geometrical stability of components is improved, as there may be less fettling of the completed product thereby reducing dimensional variation between the same components. เกจวัดแรงดัน4นิ้วราคา in turn contributes to the reliability of the gear utilizing those components. He says the foundry may even realise important environmental advantages on account of utilizing no chemicals within the sand.
“This new plant aligns well with our company sustainability targets, guaranteeing that our processes aren’t only compliant but repeatedly scale back our environmental influence,” says Smith. “Our new moulding methods be positive that fewer gases are emitted through the casting course of, and there are zero emissions of harmful substances similar to benzene.”
The new technology can be leading to less frequent disposal of silica sand, and the sand itself is more environmentally friendly because it incorporates no resin or acid.
“A exceptional facet of developing this new plant was the fact that it was done with our local skills 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 implemented on time and inside finances.”
The plant includes greater than 16,000 individual components, and uses over 1,900 m of cabling, 300 m of water piping and fifty five tons of metal.

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