Local fabricating and foundry equipment manufacturer Endeco Omega Sinto is getting ready to ship its first international order to a foundry that manufactures a range of small to large castings that meets the needs of companies in the mining, minerals, oil, gas, power and industrial markets.
The equipment manufactured locally will be assembled at the foundry site once it arrives and will be incorporated into a very large project that the foundry is currently incorporating into its current location. Endeco Omega Sinto’s contribution to the project, which is being project managed by UK parent Omega Sinto Foundry Machinery UK, includes the manufacture of two large compaction tables and the powered roller sections to move the moulding boxes. Omega Sinto Foundry Machinery UK and other subsidiary companies will be supplying the balance of the equipment for the project.
“The moulding line is referred to as a size 10. To give you some sort of comparison the biggest moulding line that has been installed in South Africa is referred to as a size 6,” said Roy Dias, Managing Director of Endeco Omega Sinto.
“We were contracted to manufacture four aspects of the overall project. All the equipment manufactured is custom designed by Omega Sinto Foundry Machinery UK and manufactured in South Africa. The scope of supply was to fabricate two compaction tables to handle moulds sized at 4 000mm by 4 000mm with capacity of 45ton, as well as two powered roller conveyors to handle same mould sizes.”
“One compaction table and the one powered roller conveyor have already been factory acceptance tested and will be shipped by the end of June 2020. The second powered roller conveyor will be ready for factory acceptance and shipping by end of June 2020. We are busy collating the packaging material and this in itself is an interesting exercise as it is a first for us.”
Endeco Omega Sinto were contracted to manufacture four aspects of the overall project. The two compaction tables are custom designed by Omega Sinto Foundry Machinery UK and manufactured in South Africa. The one table can accommodate a box with a weight of up to 45 tons and the other up to 20 tons
“At first the roller conveyors were going to be made up of solid shaft but on consultation it was decided that they would be redesigned and manufactured from Sched 120 pipes. With the rollers carrying such large moulds and weight you had to be very aware that there would not be any bowing of the individual rollers.”
“One of the biggest challenges for us was sourcing the 90 Sched 120 pipes required as they are not manufactured locally.”
“Another challenge was that we only required pipes of 4.8 metres in length, which of course is not a standard size. The only ones we could acquire come in six metre lengths. We therefore had to have them cut-to-size and we are now left with 1.2 metre off-cuts.”
“We cut them on site but finding a machine shop with machines that could handle these lengths was a huge challenge as was the machining of the pipes. Each pipe had to have machining of the O/D to required tolerance as well as the I/D of both ends by about 1 000mm so as to be fitted with shafts. Of course all have to be the exact same size as well. To find a CNC shop with lathes to accommodate 4.8 metre lengths was not easy.”
At first the roller conveyors were going to be made up of solid shaft but on consultation it was decided that they would be redesigned and manufactured from Sched 120 pipes. With the rollers carrying such large moulds and weight you had to be very aware that there would not be any bowing of the individual rollers
“We have also been responsible for the rest of the fabrication requirements and the equipment that powers a roller conveyor, which includes power belts, proximity switches, motors, gearboxes, chains and sprockets.”
“We began work on our section of the project in November last year and all items, except for the second compaction table, should be ready for shipping by the end of June 2020. This is scheduled to take place at the end of July 2020.”
Positive Group spinoffs
“This order is a direct spinoff from Endeco Omega Sinto’s move to this larger factory 18 months ago. The improvements in all aspects of our manufacturing business have led to increased orders and also recognition within the Group structure. The positive spinoff is that we are now fabricating and manufacturing company products that are destined to be installed in foundries in other countries where the Group is active.”
Endeco Omega Sinto were also responsible for the rest of the fabrication requirements and the equipment that powers a roller conveyor, which includes power belts, proximity switches, motors, gearboxes, chains and sprockets
“There are many other reasons why we are now included but one of the main reasons is that we have been acknowledged as being a fabricator and manufacturer that meets the world standards that are demanded and required. We have had to earn the trust but from a broad technical aspect we believe we are ahead in some cases. It is an opportunity that we have grasped and it is a big step as it will be the first time that we will be ‘exporting’ equipment to countries outside the continent.”
“An added advantage is the technical transfer that we are now afforded. Some of the projects that we are involved in where we are manufacturing equipment, includes equipment that we have not manufactured before.”
“Currently we are also manufacturing three different sizes of reclamation units to Omega design that will be shipped back to the UK.”