Driving down component turnaround time while enhancing 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 growth allows the company to supply extra parts at a time – and more quickly. This will assist in assembly growing buyer demand, whereas also lowering rework and wastage.
“As part of our Project Vuka, this new plant allows us to solid multiple small components per batch somewhat than just one at a time,” says Smith. “ เกจวัดแรงดันเครื่องกรองน้ำ can reduce our knock-out instances from days to just a couple of hours.”
The state-of-the-art services enable Weir Minerals Africa to solid excessive chrome components weighing up to 250 kg. There are two phases to the new course of, he explains, which uses polystyrene to create moulds. The first section is the polystyrene moulding course of, which happens after the polystyrene beads have been expanded. The second phase is the place the ramming, pouring and demoulding takes place.
In contrast to the traditional moulding line – where resin and catalyst are used to bind sand – the Replicast Plant uses 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 course of – ends in much less scrap being produced, and therefore brings operational financial savings,” he says. “The high quality of castings is also raised, with a greater floor finish and fewer defects.”
He notes that the geometrical stability of elements is improved, as there might be less fettling of the completed product thereby decreasing dimensional variation between the identical parts. This in flip contributes to the reliability of the gear using these elements. He says the foundry may even realise significant environmental benefits on account of utilizing no chemicals within the sand.
“This new plant aligns properly with our company sustainability targets, making certain that our processes usually are not solely compliant however repeatedly scale back our environmental influence,” says Smith. “Our new moulding systems make sure that fewer gases are emitted during the casting process, and there are zero emissions of dangerous substances similar to benzene.”
The new expertise can additionally be resulting in much less frequent disposal of silica sand, and the sand itself is extra environmentally friendly as it contains no resin or acid.
“A exceptional side of creating this new plant was the reality that it was carried out with our native skills 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 efficiently applied on time and within finances.”
The plant contains more than 16,000 individual components, and makes use of over 1,900 m of cabling, 300 m of water piping and fifty five tons of metal.

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