Driving down part turnaround time whereas bettering quality and lowering 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 innovative improvement enables the company to produce more elements at a time – and extra shortly. This will assist in assembly growing buyer demand, whereas additionally lowering rework and wastage.
“As part of our Project Vuka, this new plant permits us to cast multiple small parts per batch somewhat than just separately,” says Smith. “We also can reduce our knock-out occasions from days to only a couple of hours.”
The state-of-the-art amenities enable Weir Minerals Africa to cast high chrome elements weighing as a lot as 250 kg. There are two phases to the brand new process, he explains, which uses polystyrene to create moulds. The first section 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 distinction to the traditional moulding line – where resin and catalyst are used to bind sand – the Replicast Plant makes use of silica sand of 30-35 AFS grade together with the polystyrene mould, he says. The system entails a vacuum bin, from which all of the air is eliminated to compress the sand.
“The absence of resin and catalyst – as properly as having no clamping course of – ends in less scrap being produced, and due to this fact brings operational savings,” he says. “The quality of castings can be raised, with a better floor end and fewer defects.”
He notes that the geometrical stability of elements is improved, as there is less fettling of the finished product thereby reducing dimensional variation between the same elements. This in turn contributes to the reliability of the equipment utilizing those parts. He says the foundry will also realise significant environmental advantages on account of using no chemical substances in the sand.
“This new plant aligns nicely with our corporate sustainability goals, making certain that our processes usually are not solely compliant however continuously reduce our environmental impression,” says Smith. “ เกจวัดแรง make sure that fewer gases are emitted in the course of the casting process, and there are zero emissions of dangerous substances corresponding to benzene.”
The new technology is also resulting in much less frequent disposal of silica sand, and the sand itself is more environmentally pleasant because it accommodates no resin or acid.
“A outstanding side of developing this new plant was the truth that it was done with our native expertise and largely in the course of the COVID-19 lockdowns,” he says. “Despite the novelty of this know-how, and the logistical challenges created by the pandemic, it was successfully applied on time and inside budget.”
The plant consists of more than sixteen,000 individual elements, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of metal.