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WEIR MINERALS APPLIES CASTING INNOVATION AT ISANDO PLANT

Driving down part turnaround time whereas enhancing high 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 revolutionary growth allows the corporate to provide extra parts at a time – and extra quickly. This will help in meeting growing buyer demand, whereas also decreasing rework and wastage.
“As a part of our Project Vuka, this new plant allows us to solid multiple small elements per batch rather than simply one by one,” says Smith. “We also can reduce our knock-out instances from days to simply a couple of hours.”
ราคาเกจวัดแรงดัน -of-the-art facilities enable Weir Minerals Africa to cast high 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 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 normal moulding line – the place 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 – as well as having no clamping course of – ends in less scrap being produced, and subsequently brings operational financial savings,” he says. “The quality of castings can additionally be raised, with a better surface end and fewer defects.”
He notes that the geometrical stability of elements is improved, as there is less fettling of the completed product thereby lowering dimensional variation between the identical elements. This in flip contributes to the reliability of the equipment utilizing those components. He says the foundry may even realise vital environmental advantages on account of utilizing no chemicals within the sand.
“This new plant aligns well with our corporate sustainability targets, guaranteeing that our processes are not only compliant however repeatedly reduce our environmental impression,” says Smith. “Our new moulding methods ensure that fewer gases are emitted in the course of the casting process, and there are zero emissions of harmful substances such as benzene.”
The new expertise can additionally be leading to less frequent disposal of silica sand, and the sand itself is more environmentally pleasant as it contains no resin or acid.
“A exceptional aspect of creating this new plant was the truth that it was accomplished with our local abilities and largely during the COVID-19 lockdowns,” he says. “Despite the novelty of this know-how, and the logistical challenges created by the pandemic, it was efficiently applied on time and within budget.”
The plant contains greater than 16,000 individual components, and uses over 1,900 m of cabling, 300 m of water piping and 55 tons of metal.
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