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ELMACAST ENGINEERING (PTY) LTD, a foundry situated in Springs, South Africa, has recently completed phase one of its expansion project which entailed the installation of 4 new induction furnaces, 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 2500 tons a month of chrome casted grinding media for ball mills.
Further developments in the foundry included upgrades to their existing two 6 ton induction furnaces, overhaul of all cranes, newly installed shot blaster and a thermal sand reclamation plant. The foundry also produces conventional casted components in Grey Iron, SG Iron, High Chrome and Steels. These upgrades allow the foundry to produce conventional castings to a maximum gross weight of 6 tons per casting. The foundry underwent substantial upgrades to their laboratory and implemented the latest computer simulation technologies to model various casting procedures before it is executed.
Dean Wilson, General Manager of Elmacast Engineering, states that the investment into new technologies and processes was crucial for the sustainability of the company, due to the large influx of imports dominated by Chinese, Indian and Turkish markets. “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 continuity of supply.
Elmacast previously part of the Actom group was established in 1970 predominantly serving the electric motor industry by supplying casted motor casings and stator frames. Over the years the foundry expanded its product portfolio to supplying the mining, automobile and agricultural sectors with various casted components ranging from pump casings, brake drums, bearings housings and gear housing to name but a few. In March 2018 the foundry was bought out by private investors. It is now a proud level 2 BBBEE accredited company and has 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 80000m2 of which 15000m2 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 and additional induction furnaces. The second phase of the expansion project will increase the total under-roof area of the foundry to 21000m2.
The vision of the company is to become the supplier of choice by leading the way in the casting industry.