เกจ์วัดแก๊สหุงต้ม down element turnaround time whereas enhancing high quality and lowering waste is being achieved at Weir Minerals Africa’s thrilling new Replicast Plant in Isando, Gauteng.
Umar Smith, plant supervisor at Weir Minerals Africa’s Isando facility, highlights that the progressive growth allows the company to produce extra elements at a time – and more rapidly. This will help in meeting growing buyer demand, whereas also reducing rework and wastage.
“As part of our Project Vuka, this new plant permits us to cast multiple small elements per batch rather than just one by one,” says Smith. “We can also reduce our knock-out instances from days to simply a few hours.”
The state-of-the-art services allow Weir Minerals Africa to cast excessive chrome elements weighing up to 250 kg. There are two phases to the model 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 where the ramming, pouring and demoulding takes place.
In contrast to the standard moulding line – where 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 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 process – leads to 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 greater surface end and fewer defects.”
He notes that the geometrical stability of parts is improved, as there may be less fettling of the completed product thereby lowering dimensional variation between the same elements. This in turn contributes to the reliability of the tools utilizing those components. He says the foundry will also realise important environmental advantages on account of using no chemicals within the sand.
“This new plant aligns properly with our company sustainability goals, making certain that our processes aren’t only compliant but continuously scale back our environmental influence,” says Smith. “Our new moulding techniques ensure that fewer gases are emitted through the casting course of, and there are zero emissions of harmful substances corresponding to benzene.”
The new know-how is also leading to much less frequent disposal of silica sand, and the sand itself is extra environmentally friendly because it contains no resin or acid.
“A exceptional aspect of growing this new plant was the truth that it was accomplished with our native expertise 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 implemented on time and within budget.”
The plant includes more than 16,000 individual parts, and makes use of over 1,900 m of cabling, 300 m of water piping and fifty five tons of steel.
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