grinding media suppliers and manufacturing in south africa

j-tec engineering makes major contribution to grinding media south africas new induction melting plant | castings sa

Normally behind any project involving construction and or installation of equipment there are always those that help drive it and make sure that project happens. In the case of Grinding Media South Africas (GMSA) recently completed new induction melting plant, that contractor was J-Tec Engineering.

Based on our previous projects and an outstanding relationship and professional interaction with Cerefco, the South African agent for Inductotherm, J-Tec was recommended to GMSA, explained Johan Botes, J-Tec Electrical & Installations and J-Tec Engineering.

J-Tec Engineering was tasked by GMSA to establish a human capital development plan. The training system has been named the Learner Management System, is fully online and is constantly being upgraded and employees are accessing the various programmes regularly. Martin Volkwyn, the Development Manager for Grinding Media South Africa, has overseen the entire project including involving himself in the human capital development. He is seen on the right imparting knowledge to colleagues while in the custom designed control room

Our first involvement with the multi-million rand project was that J-Tec was awarded the contract to supply and install the MV (medium voltage) switchgear. Our approach to this contract opened the door to much greater things to come and later in the project J-Tec was established as one of the primary contractors on this very exciting technology upgrade project, driven by GMSAs commitment to environmental responsibilities.

J-Tec entered into negotiations to place, install and commission the equipment supplied by approximately 15 different suppliers. We were responsible for planning, organising and directing the completion of the specific installations while ensuring these installations were on time and within scope.

Human capital development During further negotiations GMSA indicated the need to establish a human capital development plan and based on previous operational experience J-Tec successfully concluded and extended our involvement and commitment towards GMSA.

GMSA has done a tremendous job planning and the amount of detail attended to beforehand was astounding. But like with any project of this nature and the magnitude of the interface of equipment other gaps were identified during installation and the commissioning phases. Due to the depth and wealth of knowledge that we have through our previous experience, J-Tec was well positioned to stimulate designs and plans to offer solutions and or alternatives to overcome these challenges.

The interaction between the human capital development and the installation team proved to be of immense value. Generic supplier manuals were responsibly customised to be project specific and user friendly. This established a firm base for training modules developed. In order to ensure longevity and to establish unrestricted access to employees, GMSA requested that the medium and approach to training be changed from trainer lead to computer-based training. The right people for this incredible challenge were provided. It needs to be stated that GMSAs commitment and the well-balanced investment in the development of their staff is unrivalled and needs to be applauded.

J-Tec Engineering was awarded the contract to supply and install the MV (medium voltage) switchgear. The companys approach to this contract opened the door to much greater things to come and later in the project J-Tec was established as one of the primary contractors. J-Tec Engineering have recently installed the Gradmatic refractory installation system at GMSA

Notwithstanding the constraints brought about by the COVID-19 pandemic, several changes to the installation plan were introduced and the initial installation was successfully completed according to the agreed schedule and within the estimated costs (excluding variational orders). The commissioning phase provided more than enough challenges of its own but the loyalty, commitment and dedication of the J-Tec team shone through. At the onset of commissioning, GMSA highlighted the need to provide, on shift, practical training, guidance and oversight of the theoretically trained delegates and yet again J-Tec stepped forward and plugged that gap.

Currently J-Tec is involved with ongoing problem solving, maintenance and the finalisation of the competence declaration of GMSA personnel, whilst at the same time on-the-job training is provided to the technical team.

For nearly thirty years, Gradmatic Equipment has significantly influenced the foundry industry by providing innovative technology to line coreless induction furnaces with dry, refractory materials. Specialising in refractory installation and vibration, their product primarily focuses on improving the industrial furnace lining process for worker safety and efficiency.

Future We are busy negotiating to look after the sales and service of Gradmatics equipment in South Africa. However, it is our ambition to not only get involved with projects in South Africa similar to this one at GMSA but also in the rest of Africa. We were hugely involved with the installation of the furnaces including the VIP control equipment, transformers, the water cooling and the hydraulic equipment. We are very electrical and general engineering savvy now and can call on many installation experiences.

inductotherm introduces some firsts into grinding media south africas new induction melting plant | castings sa

One of the main suppliers for Grinding Media South Africas (GMSA) new induction furnace melting plant Inductotherm, represented in South Africa by Cerefco, has introduced a number of firsts for the South African metal melting industry while installing three 10 ton Inductotherm coreless induction furnaces.

I Plant Minder melt control and management system Custom designed according to GMSAs requirement and introduced for the first time in South Africa was the I Plant Minder is melt shop control and management system providing precise, highly responsive and fully programmable control which is important to the safe and efficient operation of todays induction melting equipment.

Inductotherms high-velocity fume extraction hood, the Vortex hood, has been introduced into South Africa for the first time and are being used on the three 10 ton Inductotherm coreless induction furnaces with VIP Power Trak power supply

The system is PLC-based and designed around an industrial Ethernet network. It provides the furnace operator with the tools needed to monitor the entire melting process, from charging to melting to pouring. The system also provides melt shop supervisors and managers with the broad range of data they need to monitor, evaluate and plan melt shop operations. The custom configuration provides operational settings for your furnaces and power supplies as well as for the water system.

Vortex high-velocity fume extraction hood Inductotherms high-velocity fume extraction hood, the Vortex hood, has also been introduced into South Africa for the first time. They are designed for induction furnace applications to extract fumes more effectively during various operations such as charging, slagging, temperature taking, sampling, melting, holding, pouring and lining push out.

Custom designed according to GMSAs requirement and introduced for the first time in South Africa was I Plant Minder melt control and management system. The custom configuration provides operational settings for your furnaces and power supplies as well as for water system

The Vortex extraction hood is hydraulically operated with a telescoping duct and internal electrical interlocking sensors. The telescopic duct provides a stationary connection to the plant duct work regardless of the furnace or hood position.

The Vortex high-velocity extraction hood offers greater flexibility since it incorporates two independently operated cylinders. These cylinders allow the hood to have a greater range of movement to allow a better access during a wide range of both operational and maintenance tasks.