Driving down element turnaround time while enhancing high quality and decreasing waste is being achieved at Weir Minerals Africa’s exciting new Replicast Plant in Isando, Gauteng.
Umar Smith, plant manager at Weir Minerals Africa’s Isando facility, highlights that the innovative development permits the corporate to provide more elements at a time – and extra shortly. This will help in assembly growing buyer demand, whereas also decreasing rework and wastage.
“As part of our Project Vuka, this new plant permits us to solid multiple small components per batch rather than simply one by one,” says Smith. “We can even scale back our knock-out occasions from days to only a couple of hours.”
The state-of-the-art amenities allow Weir Minerals Africa to solid excessive chrome components weighing up to 250 kg. There are two phases to the model new process, he explains, which uses polystyrene to create moulds. The first section is the polystyrene moulding process, which happens after the polystyrene beads have been expanded. The second part 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 includes a vacuum bin, from which all 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 due to this fact brings operational savings,” he says. “ เกจวัดแรงดันน้ำไทวัสดุ of castings can be raised, with a greater floor finish and fewer defects.”
He notes that the geometrical stability of components is improved, as there might be less fettling of the finished product thereby decreasing dimensional variation between the same parts. This in turn contributes to the reliability of the gear utilizing these parts. He says the foundry may even realise significant environmental advantages on account of using no chemicals within the sand.
“This new plant aligns nicely with our company sustainability objectives, guaranteeing that our processes aren’t solely compliant but continuously scale back our environmental influence,” says Smith. “Our new moulding systems be sure 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 technology is also leading to much less frequent disposal of silica sand, and the sand itself is more environmentally friendly because it incorporates no resin or acid.
“A remarkable aspect of developing this new plant was the truth that it was carried out with our local expertise and largely during the COVID-19 lockdowns,” he says. “Despite the novelty of this technology, and the logistical challenges created by the pandemic, it was efficiently implemented on time and inside finances.”
The plant contains greater than sixteen,000 individual elements, and uses over 1,900 m of cabling, 300 m of water piping and fifty five tons of steel.