Driving down part turnaround time whereas bettering high quality and decreasing waste is being achieved at Weir Minerals Africa’s thrilling new Replicast Plant in Isando, Gauteng.
Umar Smith, plant manager at Weir Minerals Africa’s Isando facility, highlights that the revolutionary improvement enables the corporate to produce more components at a time – and more quickly. This will assist in assembly rising customer demand, whereas additionally lowering rework and wastage.
“As ไดอะแฟรม of our Project Vuka, this new plant allows us to cast multiple small parts per batch quite than simply one by one,” says Smith. “We can also scale back our knock-out times from days to simply a few hours.”

The state-of-the-art services enable Weir Minerals Africa to cast excessive chrome elements weighing up to 250 kg. There are two phases to the model new process, he explains, which makes use of polystyrene to create moulds. The first part is the polystyrene moulding course of, which occurs after the polystyrene beads have been expanded. The second phase is the place the ramming, pouring and demoulding takes place.
In distinction to the normal 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 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 – leads to less scrap being produced, and subsequently brings operational savings,” he says. “The quality of castings can be raised, with a better floor finish and fewer defects.”

He notes that the geometrical stability of components is improved, as there is less fettling of the finished product thereby decreasing dimensional variation between the identical components. digital pressure gauge in turn contributes to the reliability of the equipment utilizing those elements. He says the foundry will also realise important environmental benefits as a result of utilizing no chemical substances in the sand.
“This new plant aligns nicely with our corporate sustainability objectives, ensuring that our processes usually are not solely compliant however repeatedly cut back our environmental impression,” says Smith. “Our new moulding systems be positive that fewer gases are emitted during the casting process, and there are zero emissions of dangerous substances corresponding to benzene.”

The new technology is also resulting in less frequent disposal of silica sand, and the sand itself is more environmentally friendly because it accommodates no resin or acid.
“A remarkable side of creating this new plant was the reality that it was accomplished 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 implemented on time and within finances.”

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

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