Driving down component turnaround time whereas bettering high quality and decreasing waste is being achieved at Weir Minerals Africa’s exciting new Replicast Plant in Isando, Gauteng.
Umar Smith, plant supervisor at Weir Minerals Africa’s Isando facility, highlights that the revolutionary growth permits the company to provide extra parts at a time – and more quickly. This will assist in assembly rising customer demand, while also decreasing rework and wastage.
“As part of our Project Vuka, this new plant permits us to solid a number of small parts per batch quite than simply one at a time,” says Smith. “We can even cut back our knock-out instances from days to just a few hours.”

The state-of-the-art amenities allow Weir Minerals Africa to solid excessive chrome components weighing as much as 250 kg. There are two phases to the brand new process, he explains, which uses polystyrene to create moulds. The first part is the polystyrene moulding course of, which occurs after the polystyrene beads have been expanded. pressure gauge octa is the place the ramming, pouring and demoulding takes place.
In contrast to the normal 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 together with the polystyrene mould, he says. The system entails 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 course of – results in much less scrap being produced, and subsequently 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 parts is improved, as there’s less fettling of the completed product thereby lowering dimensional variation between the same parts. This in flip contributes to the reliability of the tools utilizing these parts. He says the foundry may also realise important environmental advantages because of using no chemical substances within the sand.
“This new plant aligns well with our corporate sustainability goals, guaranteeing that our processes usually are not solely compliant however repeatedly scale back our environmental impact,” says Smith. “Our new moulding systems ensure that fewer gases are emitted in the course of the casting course of, and there are zero emissions of dangerous substances such as benzene.”

The new know-how can be resulting in much less frequent disposal of silica sand, and the sand itself is extra environmentally pleasant because it incorporates no resin or acid.
“A exceptional facet of growing this new plant was the truth that it was carried out with our local skills and largely during the COVID-19 lockdowns,” he says. “Despite the novelty of this know-how, and the logistical challenges created by the pandemic, it was successfully carried out on time and inside price range.”

The plant consists of greater than sixteen,000 individual components, and makes use of over 1,900 m of cabling, 300 m of water piping and fifty five tons of steel.