Elmacast Engineering, a foundry based in Springs, Gauteng, has recently completed phase one of its expansion project that entailed the installation of four new induction furnaces, an automated continuous caster and a fully integrated double line heat treatment plant. The cost of the project totalled R134 million, which increased the foundry’s capacity to produce in excess of 2 500 tons a month of grinding media comprising high chrome balls.
Further developments in the foundry included upgrades to the existing two 6-ton induction furnaces, an overhaul of all cranes as well as the installation of a shot blasting machine and a thermal sand reclamation plant. The foundry also produces conventional cast components in grey iron, SG iron, high chrome and various steels. These upgrades allow the foundry to produce conventional castings to a maximum gross weight of six tons per casting.
Additionally, the foundry has undergone substantial upgrades to the laboratory and implemented the latest computer simulation technologies to model various casting procedures before they are executed.
“The investment into new technologies and processes was crucial for the sustainability of the company, due to the large influx of imports emanating from the Chinese, Indian and Turkish markets,” said Dean Wilson, General Manager of Elmacast Engineering.
“These upgrades give Elmacast Engineering a competitive edge while allowing further focus on quality to ensure world class castings are delivered to our customers.”
Dean Wilson further commented that over and above the new equipment and technologies invested in the foundry, strategic supply contracts of raw materials were put in place to ensure materials are sourced at the right price, quality and the continuity of supply.
Elmacast, which was previously part of the Actom Group, was established in 1970 predominantly serving the electric motor industry by supplying motor casings and stator frames. Over the years the foundry expanded its product portfolio to supplying the mining, automobile and agricultural sectors with various components ranging from pump casings, brake drums, bearing housings and gear housings, to name a few.
In March 2018 the foundry business was purchased by private investors. It is now a proud level 2 BBBEE accredited company and achieved its ISO 9001, 14001 and 45001:2015 certification in January of this year. The installation of new equipment and renovations in the foundry started in April 2018 with the first castings being produced in November 2018.
The size of the property owned by Elmacast Engineering totals over 80 000m² of which
15 000m² is currently under roof. The foundry is now undergoing phase two of its expansion project, which will add additional capacity to its grinding media offering as well as another high-volume production line for smaller conventional castings. Additional induction furnaces will also be installed. The second phase of the expansion project will increase the total under-roof area of the foundry to 21 000m².
For further details contact Elmacast Engineering on TEL: 011 818 3511