Driving down part turnaround time whereas enhancing high quality and reducing 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 permits the corporate to supply extra elements at a time – and more shortly. This will help in assembly growing buyer demand, whereas additionally reducing rework and wastage.
“As a part of our Project Vuka, this new plant allows us to cast multiple small parts per batch somewhat than simply one by one,” says Smith. “We also can scale back our knock-out times from days to simply a couple of hours.”
The state-of-the-art services enable Weir Minerals Africa to forged excessive chrome parts weighing up to 250 kg. There are two phases to the new process, he explains, which makes use of polystyrene to create moulds. pressure gauge น้ำมัน is the polystyrene moulding course of, which happens after the polystyrene beads have been expanded. The second part is the place 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 makes use of silica sand of 30-35 AFS grade along with the polystyrene mould, he says. The system involves a vacuum bin, from which all of the air is eliminated to compress the sand.
“The absence of resin and catalyst – as properly as having no clamping process – leads to less scrap being produced, and subsequently brings operational savings,” he says. “The high quality of castings is also raised, with a better surface finish and fewer defects.”
He notes that the geometrical stability of elements is improved, as there could be less fettling of the finished product thereby decreasing dimensional variation between the same elements. This in flip contributes to the reliability of the tools utilizing these parts. He says the foundry will also realise important environmental benefits because of utilizing no chemicals in the sand.
“This new plant aligns properly with our corporate sustainability targets, guaranteeing that our processes are not solely compliant but continuously reduce our environmental influence,” says Smith. “Our new moulding systems make certain that fewer gases are emitted during the casting course of, and there are zero emissions of harmful substances corresponding to benzene.”
The new know-how is also resulting in much less frequent disposal of silica sand, and the sand itself is extra environmentally pleasant as it accommodates no resin or acid.
“A outstanding side of creating this new plant was the truth that it was carried out with our native abilities 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 inside finances.”
The plant consists of greater than 16,000 individual parts, and uses over 1,900 m of cabling, 300 m of water piping and 55 tons of metal.

Scroll to Top