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Driving down element turnaround time while enhancing quality and decreasing 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 improvement enables the corporate to produce extra elements at a time – and more quickly. This will help in meeting growing customer demand, while also lowering rework and wastage.
“As part of our Project Vuka, this new plant allows us to cast a number of small elements per batch rather than just one at a time,” says Smith. “We can also reduce our knock-out occasions from days to just a couple of hours.”
The state-of-the-art services allow Weir Minerals Africa to solid excessive chrome components weighing up to 250 kg. There are two phases to the model new course of, he explains, which makes use of polystyrene to create moulds. The first section is the polystyrene moulding process, 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 – the place resin and catalyst are used to bind sand – the Replicast Plant makes use of silica sand of 30-35 AFS grade together with the polystyrene mould, he says. The system entails a vacuum bin, from which all the air is eliminated to compress the sand.
“The absence of resin and catalyst – in addition to having no clamping course of – leads to much less scrap being produced, and subsequently brings operational financial savings,” he says. “The high quality of castings can also be raised, with a better floor end and fewer defects.”
He notes that the geometrical stability of components is improved, as there might be less fettling of the finished product thereby lowering dimensional variation between the identical elements. This in turn contributes to the reliability of the tools using these components. He says the foundry may also realise significant environmental benefits because of utilizing no chemical compounds within the sand.
“This new plant aligns nicely with our corporate sustainability objectives, making certain that our processes aren’t only compliant but constantly reduce our environmental impact,” says Smith. “ ร้านซ่อมเครื่องวัดความดัน ensure that fewer gases are emitted in the course of the casting process, and there are zero emissions of dangerous substances corresponding to benzene.”
The new know-how can also be resulting in less frequent disposal of silica sand, and the sand itself is extra environmentally pleasant as it accommodates no resin or acid.
“A outstanding side of developing this new plant was the fact that it was done with our native 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 successfully applied on time and within finances.”
The plant consists of more than sixteen,000 individual parts, 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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