Driving down component turnaround time whereas enhancing high quality and lowering waste is being achieved at Weir Minerals Africa’s thrilling new Replicast Plant in Isando, Gauteng.
Umar Smith, plant manager at Weir Minerals Africa’s Isando facility, highlights that the innovative improvement allows the company to supply extra parts at a time – and more rapidly. This will help in meeting rising buyer demand, while additionally lowering rework and wastage.
“As part of our Project Vuka, this new plant permits us to cast a number of small elements per batch rather than just separately,” says Smith. “We can also scale back our knock-out times from days to just a few hours.”
The state-of-the-art services allow Weir Minerals Africa to cast excessive chrome components weighing as a lot as 250 kg. There are two phases to the model new course of, he explains, which makes use of polystyrene to create moulds. The first phase is the polystyrene moulding process, 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 together with the polystyrene mould, he says. The system involves 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 course of – ends in much less scrap being produced, and due to this fact brings operational savings,” he says. “The quality of castings is also raised, with a greater surface finish and fewer defects.”
He notes that the geometrical stability of elements is improved, as there could be less fettling of the finished product thereby lowering dimensional variation between the identical parts. pressure gauge หน้าปัด 2 นิ้ว in turn contributes to the reliability of the gear using those parts. He says the foundry may even realise significant environmental advantages as a end result of using no chemical substances within the sand.
“This new plant aligns well with our company sustainability targets, ensuring that our processes usually are not solely compliant but continuously scale back our environmental impression,” says Smith. “Our new moulding methods be sure that fewer gases are emitted through the casting course of, and there are zero emissions of dangerous substances such as benzene.”
The new know-how is also 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 facet of growing this new plant was the fact that it was accomplished with our local abilities 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 inside price range.”
The plant includes more than sixteen,000 particular person parts, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of metal.