Driving down component turnaround time while bettering high quality and lowering 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 innovative growth enables the corporate to supply more parts at a time – and more shortly. This will help in meeting rising customer demand, whereas also lowering rework and wastage.
“As a part of our Project Vuka, this new plant allows us to cast a number of small parts per batch rather than simply separately,” says Smith. “ ไดอะแฟรม ซีล can also scale back our knock-out instances from days to only a few hours.”

The state-of-the-art facilities allow Weir Minerals Africa to cast excessive chrome parts weighing as a lot as 250 kg. There are diaphragm seal 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 where the ramming, pouring and demoulding takes place.
In distinction to the traditional 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 includes a vacuum bin, from which all of the air is removed to compress the sand.
“The absence of resin and catalyst – in addition to having no clamping course of – results in less scrap being produced, and subsequently brings operational savings,” he says. “The quality of castings can additionally be raised, with a greater surface end and fewer defects.”

He notes that the geometrical stability of elements is improved, as there’s much less fettling of the finished product thereby reducing dimensional variation between the same parts. This in turn contributes to the reliability of the equipment utilizing these parts. He says the foundry may even realise vital environmental advantages because of utilizing no chemical substances within the sand.
“This new plant aligns nicely with our company sustainability goals, guaranteeing that our processes usually are not only compliant but repeatedly reduce our environmental influence,” says Smith. “Our new moulding techniques ensure that fewer gases are emitted during the casting course of, and there are zero emissions of dangerous substances such as benzene.”

The new expertise can be leading to less frequent disposal of silica sand, and the sand itself is more environmentally pleasant because it contains no resin or acid.
“A remarkable aspect of growing this new plant was the fact that it was done with our local abilities and largely through the COVID-19 lockdowns,” he says. “Despite the novelty of this expertise, and the logistical challenges created by the pandemic, it was efficiently implemented on time and within 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 metal.

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