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WEIR MINERALS APPLIES CASTING INNOVATION AT ISANDO PLANT

Driving down element turnaround time whereas enhancing high quality and decreasing 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 development enables the company to produce more components at a time – and more shortly. This will help in meeting growing customer demand, while additionally decreasing rework and wastage.
“As a part of our Project Vuka, this new plant allows us to solid a quantity of small parts per batch somewhat than simply one at a time,” says Smith. “ ไดอะแฟรม can even scale back our knock-out instances from days to only a few hours.”

The state-of-the-art services allow Weir Minerals Africa to solid high chrome parts weighing as a lot as 250 kg. There are two phases to the model new process, he explains, which uses polystyrene to create moulds. The first part is the polystyrene moulding process, 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 traditional moulding line – where 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 entails a vacuum bin, from which all of the air is eliminated to compress the sand.
“The absence of resin and catalyst – as properly as having no clamping course of – results in less scrap being produced, and subsequently brings operational savings,” he says. “The high quality of castings is also raised, with a greater surface end and fewer defects.”

He notes that the geometrical stability of elements is improved, as there could be less fettling of the completed product thereby lowering dimensional variation between the identical components. This in flip contributes to the reliability of the equipment utilizing those components. He says the foundry may even realise important environmental advantages as a end result of using no chemical substances within the sand.
“This new plant aligns nicely with our corporate sustainability objectives, ensuring that our processes are not only compliant but constantly reduce our environmental impact,” says Smith. “Our new moulding systems be sure 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 friendly because it accommodates no resin or acid.
“A remarkable facet of creating this new plant was the fact that it was done with our native abilities 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 efficiently carried out on time and within finances.”

The plant includes greater than 16,000 individual components, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.
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