Driving down element turnaround time while improving high quality and reducing waste is being achieved at Weir Minerals Africa’s exciting new Replicast Plant in Isando, Gauteng.
Umar Smith, plant supervisor at Weir Minerals Africa’s Isando facility, highlights that the revolutionary improvement permits the corporate to provide extra components at a time – and more rapidly. This will assist in assembly growing buyer demand, while additionally reducing rework and wastage.
“As part of our Project Vuka, this new plant permits us to forged multiple small components per batch quite than simply separately,” says Smith. “We can even cut 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 elements weighing up to 250 kg. There are two phases to the new course of, he explains, which makes use of polystyrene to create moulds. The first section 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 contrast to the standard 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 includes a vacuum bin, from which all the air is removed to compress the sand.
เกจวัดแรงกด of resin and catalyst – in addition to having no clamping course of – ends in less scrap being produced, and due to this fact brings operational financial savings,” he says. “The high quality of castings can be raised, with a greater surface end and fewer defects.”
He notes that the geometrical stability of elements is improved, as there’s less fettling of the finished product thereby decreasing dimensional variation between the identical parts. This in flip contributes to the reliability of the tools utilizing these parts. He says the foundry may also realise significant environmental benefits because of using no chemicals in the sand.
“This new plant aligns well with our corporate sustainability objectives, guaranteeing that our processes usually are not only compliant but continuously reduce our environmental influence,” says Smith. “Our new moulding techniques be certain that fewer gases are emitted in the course of the casting course of, and there are zero emissions of dangerous substances corresponding to benzene.”
The new expertise is also resulting in less frequent disposal of silica sand, and the sand itself is extra environmentally pleasant as it contains no resin or acid.
“A exceptional facet of creating this new plant was the truth that it was accomplished with our local skills and largely in the course of the COVID-19 lockdowns,” he says. “Despite the novelty of this expertise, and the logistical challenges created by the pandemic, it was successfully applied on time and within budget.”
The plant consists of greater than 16,000 individual elements, and uses over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.

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