Driving down element turnaround time while improving high quality and reducing waste is being achieved at Weir Minerals Africa’s thrilling new Replicast Plant in Isando, Gauteng.
เกจวัดแรงดันแก๊สอาร์กอน , plant manager at Weir Minerals Africa’s Isando facility, highlights that the revolutionary development allows the corporate to supply extra components at a time – and more shortly. This will help in assembly rising customer demand, while also reducing rework and wastage.
“As part of our Project Vuka, this new plant allows us to forged multiple small components per batch quite than simply separately,” says Smith. “We can also scale back our knock-out occasions from days to simply a couple of hours.”
The state-of-the-art amenities allow Weir Minerals Africa to forged excessive chrome components weighing as a lot as 250 kg. There are two phases to the new process, he explains, which uses polystyrene to create moulds. The first section is the polystyrene moulding process, which happens after the polystyrene beads have been expanded. The second section is the place the ramming, pouring and demoulding takes place.
In contrast to the standard 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 involves 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 process – leads to much less scrap being produced, and due to this fact 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 parts is improved, as there is much less fettling of the finished product thereby decreasing dimensional variation between the identical components. This in turn contributes to the reliability of the equipment utilizing these elements. He says the foundry may even realise significant environmental advantages on account of utilizing no chemicals within the sand.
“This new plant aligns properly with our company sustainability targets, guaranteeing that our processes are not solely compliant however repeatedly scale back our environmental impression,” says Smith. “Our new moulding techniques be certain that fewer gases are emitted during the casting process, and there are zero emissions of dangerous substances such as benzene.”
The new technology is also resulting in less frequent disposal of silica sand, and the sand itself is more environmentally pleasant because it accommodates no resin or acid.
“A exceptional aspect of growing this new plant was the reality that it was done with our local abilities and largely in the course of the COVID-19 lockdowns,” he says. “Despite the novelty of this technology, and the logistical challenges created by the pandemic, it was successfully carried out on time and within budget.”
The plant includes greater than sixteen,000 individual parts, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.