Driving down part turnaround time whereas bettering 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 progressive development enables the company to produce extra parts at a time – and extra rapidly. This will help in meeting rising customer demand, whereas additionally decreasing rework and wastage.
“As part of our Project Vuka, this new plant permits us to cast a quantity of small parts per batch somewhat than simply one by one,” says Smith. “We can even cut back our knock-out occasions from days to simply a few hours.”
The state-of-the-art facilities enable Weir Minerals Africa to forged high chrome parts weighing as much as 250 kg. There are two phases to the new course of, he explains, which uses polystyrene to create moulds. The first phase is the polystyrene moulding course of, which occurs 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 – 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 entails a vacuum bin, from which all of the air is eliminated to compress the sand.
“The absence of resin and catalyst – as nicely as having no clamping process – leads to much less scrap being produced, and subsequently brings operational financial savings,” he says. “The quality of castings can also be raised, with a better floor end and fewer defects.”
เกจ์วัดแรงดันน้ำ notes that the geometrical stability of components is improved, as there could be less fettling of the completed product thereby lowering dimensional variation between the same elements. This in turn contributes to the reliability of the equipment utilizing those components. He says the foundry will also realise vital environmental advantages as a result of using no chemical compounds in the sand.
“This new plant aligns nicely with our corporate sustainability goals, making certain that our processes are not solely compliant but continuously scale back our environmental impact,” says Smith. “Our new moulding systems make certain that fewer gases are emitted through the casting course of, and there are zero emissions of dangerous substances corresponding to benzene.”
The new know-how is also resulting in much less frequent disposal of silica sand, and the sand itself is more environmentally friendly because it incorporates no resin or acid.
“A outstanding facet of growing this new plant was the truth that it was done with our local skills 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 efficiently implemented on time and within finances.”
The plant consists of more than 16,000 individual elements, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.

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