Driving down component turnaround time whereas enhancing 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 progressive growth allows the company to provide extra elements at a time – and more rapidly. This will assist in assembly rising customer demand, while also lowering rework and wastage.
“As a half of our Project Vuka, this new plant allows us to solid multiple small elements per batch somewhat than simply one at a time,” says Smith. “We can even cut back our knock-out times from days to just a few hours.”
The state-of-the-art amenities allow Weir Minerals Africa to forged excessive chrome components weighing up to 250 kg. There are two phases to the 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 section is where the ramming, pouring and demoulding takes place.
In pressure gauge วัด แรง ดัน น้ำ to the standard moulding line – where 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 includes a vacuum bin, from which all the air is removed to compress the sand.
“The absence of resin and catalyst – as properly as having no clamping process – ends in less scrap being produced, and therefore brings operational financial savings,” he says. “The high quality of castings can be raised, with a better floor end and fewer defects.”
He notes that the geometrical stability of components is improved, as there’s much 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 parts. He says the foundry may even realise significant environmental benefits as a end result of utilizing no chemical substances in the sand.
“This new plant aligns well with our company sustainability goals, making certain that our processes aren’t solely compliant however continuously scale back our environmental influence,” says Smith. “Our new moulding methods be certain that fewer gases are emitted through the casting course of, and there are zero emissions of harmful substances such as benzene.”
The new technology can be leading to much less frequent disposal of silica sand, and the sand itself is more environmentally pleasant as it contains no resin or acid.
“A remarkable side of creating this new plant was the fact that it was done with our local expertise and largely through the COVID-19 lockdowns,” he says. “Despite the novelty of this technology, and the logistical challenges created by the pandemic, it was successfully applied on time and within budget.”
The plant includes more than sixteen,000 particular person components, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.