Driving down part turnaround time while improving 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 progressive growth enables the corporate to provide extra components at a time – and extra rapidly. pressure gauge น้ำมัน will assist in meeting rising buyer demand, whereas additionally reducing rework and wastage.
“As a part of our Project Vuka, this new plant permits us to forged multiple small components per batch quite than just separately,” says Smith. “We can also reduce our knock-out times from days to just a few hours.”
The state-of-the-art services allow Weir Minerals Africa to forged excessive chrome components weighing up to 250 kg. There are two phases to the brand new course of, he explains, which makes use of polystyrene to create moulds. เกจวัดความดันแก๊ส is the polystyrene moulding course of, which occurs after the polystyrene beads have been expanded. The second part is where 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 together with the polystyrene mould, he says. The system includes a vacuum bin, from which all of the air is eliminated to compress the sand.
“The absence of resin and catalyst – in addition to having no clamping process – leads to less scrap being produced, and therefore brings operational savings,” he says. “The high quality of castings can also be raised, with a greater surface end and fewer defects.”
He notes that the geometrical stability of components is improved, as there may be less fettling of the finished product thereby decreasing dimensional variation between the same elements. This in turn contributes to the reliability of the tools using those elements. He says the foundry will also realise significant environmental advantages as a outcome of utilizing no chemicals within the sand.
“This new plant aligns properly with our company sustainability goals, making certain that our processes are not only compliant however repeatedly scale back our environmental impression,” says Smith. “Our new moulding methods be positive that fewer gases are emitted through the casting process, and there are zero emissions of harmful substances such as benzene.”
The new technology can also be resulting in much less frequent disposal of silica sand, and the sand itself is extra environmentally pleasant as it contains no resin or acid.
“A remarkable facet of creating this new plant was the reality that it was carried out with our local skills 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 applied on time and within budget.”
The plant consists of more than sixteen,000 particular person elements, and uses over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.

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