Driving down part turnaround time while improving quality and decreasing waste is being achieved at Weir Minerals Africa’s thrilling new Replicast Plant in Isando, Gauteng.
เพรสเชอร์เกจน้ำ , plant supervisor at Weir Minerals Africa’s Isando facility, highlights that the innovative development allows the corporate to provide extra elements at a time – and extra shortly. This will help in assembly rising buyer demand, while also reducing rework and wastage.
“As part of our Project Vuka, this new plant allows us to solid a quantity of small components per batch rather than simply one at a time,” says Smith. “We also can reduce our knock-out times from days to just a couple of hours.”
The state-of-the-art facilities enable Weir Minerals Africa to forged excessive chrome elements weighing as a lot as 250 kg. There are two phases to the new process, 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 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.
ตัววัดแรงดันน้ำมัน of resin and catalyst – as nicely as having no clamping course of – results in less scrap being produced, and therefore 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 parts is improved, as there’s less fettling of the finished product thereby decreasing dimensional variation between the identical elements. This in turn contributes to the reliability of the tools utilizing those elements. He says the foundry will also realise important environmental benefits because of using no chemical compounds within the sand.
“This new plant aligns nicely with our corporate sustainability goals, making certain that our processes aren’t only compliant however continuously scale back our environmental influence,” says Smith. “Our new moulding methods make certain that fewer gases are emitted in the course of the casting course of, and there are zero emissions of harmful substances similar to benzene.”
The new expertise can be leading to much less frequent disposal of silica sand, and the sand itself is extra environmentally friendly as it incorporates no resin or acid.
“A outstanding facet of developing this new plant was the truth that it was accomplished with our native expertise and largely through 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 budget.”
The plant consists of more than sixteen,000 particular person elements, and makes use of over 1,900 m of cabling, 300 m of water piping and fifty five tons of steel.

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