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Friday, 31 May 2013


The Bretonstone® story is one of a dream come true, an integral part of Breton SpA - 50 years of technological innovation; a global leader in the field, proud of the “Italian” heritage. We have never believed in delocalization, and made the creativity and professional qualities found here in Italy the cornerstones of our company.
Sir Marcello Toncelli

But above all, this is the story of the man who established the company, Sir Marcello Toncelli, and of all those who believed in what he was doing, and helped him make the Bretonstone® dream come true.
Brevetti Toncelli was established in 1963 at Castello di Godego in the province of Treviso, and this first firm changed its name to Bre-Ton and finally Breton; focused in the production of machinery for working natural stone, the company soon began developing technologies and plants for the production of what was once commonly called “agglomerate” as it is made of stone fragments bonded together by resins, now known as Engineered Stone. 
Luca and Dario Toncelli
Today Breton is run by Mr. Toncelli's heirs Luca and Dario, and has made its name all over the world as a company that has made research its motto, employing approximately 600 people in the four Veneto production plants and in the foreign-based companies, with an estimated annual turnover for 2013 of over 150 Million EURO.
All the company's closest collaborators say the founding father Marcello Toncelli was always one step ahead of the rest, sometimes even so far ahead he might at times seem rash, but he had a dream, and the insight, the passion and doggedness to make that dream come true! He knew the future lay in an industrial stone product that could be mass produced in as many square meters as were required, in the same color, with the same structure, and all…at the press of a button!
Bretonstone® was made of blocks of polyester resin and fragments of marble, materials which were poured by hand into the ( 30 x 50 cm) formworks, to be first compacted and then cut into tiles; later bigger blocks (300 x 125 cm) were used, and the resulting slabs had a “Palladiana” (crazy paving) type finish.
This was the early 70's; and the innovative idea was to give the material a different kind of look, similar to granite, using small rather than large aggregates, with the possibility of producing slabs instead of blocks that needed cutting
And so the idea and the “Great”
Bretonstone® dream was born, and we were taking bets we'd make that dream come true! We developed many new technologies and inventions, all of which protected by patents.
Bretonstone® plant prototype
There were problems at first that took a long time to resolve, some of which are fondly remembered in time, like when Marcello Toncelli came up with the memorable “hot water bottle” solution: the first products were subject to porosity, as air bubbles got trapped in the resin; Toncelli came up with the idea of putting the mix in a vacuum, and the only thing he could think of at the time to do this was a hot water bottle: he poured in the mix, screwed tight the plug, beat the bottle with a hammer on a bit of wood to make the mix more compact and put the lot in the oven to cure; when the rubber was peeled back, the first Bretonstone® tile was born! 
Thanks to the vacuum the product was now free of porosity and the particle size effect of the aggregates was emphasized: success at last!
Now all we had to do was come up with a way to use this “hot water bottle” idea on a larger scale and in mass production.
Large slabs were difficult to produce, and had a tendency to curve when curing: it took years to find the technical solutions required to make the product perfect, and the development of our vibro-compression vacuum technology to use mixes with a minimum polyester resin content was a big breakthrough.

First Bretonstone® plant
Finally, after years of experimentation and research, the first Bretonstone® plant for the production of 125 x 125 cm slabs was ready to go into production, and this first plant was sold in 1979 to Caremac based in Tunisia; another of these plants was soon sold to a company in Venezuela, to be followed by another for Stone Italiana of Verona; and others in Singapore, followed by Hidaque in Spain, Santa Margherita in Italy, and Armstrong Flooring in the US.
First Bretonstone® plant
As with all new products, it took time for Bretonstone® to make its name; for the market to realise its potential, with many showroom installations. Architects didn't know how the resin would behave in time, when exposed to the sun and atmospheric agents. They feared it could be scratched and scuffed; at first there was a great deal of scepticism, but here at Breton we believed in our product.
First Bretonstone® plant
The first Bretonstone® was characterised by a property that was considered a limit by the market: despite the fact it looked like granite, the mix of polyester resin and marble aggregates was physically more similar to marble: not as hard as granite.
To obtain the same hardness as granite, we had to use siliceous stone or quartz in the mix, but this was harder to work
First Bretonstone® plant
In the late 1970's Breton invented a machine for polishing hard natural stone in a production line; stone polishing machines with heads fitted with oscillating sectors, the ground-breaking Levibreton KG was an instant success all over the world in the early 1980's.
This lead to the idea of producing
Bretonstone® with hard aggregates such as silica sand, quartz, granite: in 1982 we supplied Saro of Trento with a plant for the production of 125 x 125 cm Bretonstone slabs made of granular porphyry, and in 1984 a similar plant was supplied to the UK-based company Marble Work owned by Mr. Juma for the production of slabs made of silica sand, polished with heads fitted with oscillating sectors.
Caesarstone plant testing
Bretonstone® was now just as beautiful as granite, but offered much better performance: more resistant and non-absorbent; soon, all Bretonstone® manufacturers switched to silica sand and/or quartz mixes.
It was the natural evolution of things: in 1987 the Israeli company Caesar Stone bought the first
Bretonstone® plant using new technology for the production of large (125x308 cm) slabs; at first the plant was designed to use granulated marble, but it was immediately converted to produce slabs made of silica sand and then ground quartz, in consideration of the fantastic results obtained in the UK plant
Bretonstone® modern plant
It was a great success for the company; now quoted on the New York NASDAQ stock market, and the owner of 4 plants, soon to become 6. 
Also in Spain, Cosentino, who had bought a plant to use waste from their Macael white marble quarry in 1989, later switched production to quartz with Silestone, and this resulted in exponential growth, also thanks to the successful and effective marketing policy developed in the North American market: a first plant was soon followed by a second, a third, the forth, and the company now owns 11 and is the greatest producer of Bretonstone® quartz in the world.
Bretonstone® modern plant

The size of our slabs has evolved in time, with the width increasing from 125 to 144 and then 166 cm; today Breton can offer its customers plants based on truly innovative technology to produce “Bretonstone® Jumbo” (212 x 367 cm) slabs of an absolutely amazing aesthetic quality, a delight to behold with an infinite number of possible configurations!
Bretonstone® JUMBO slab
The look has also evolved over the years: first granite-looking, then one-color, to be followed by veined marble and today also our “exotic granite” effect, similar to certain rare and costly Brazilian granites, such as the stone produced by Cambria in Minnesota and others.
Each manufacturer has added their own personal touch to the aesthetic quality of the product, with exquisite colored glass inserts, crystal, mirrors, semi-precious stones, or brass filings to “speckle the stone with gold”, transforming Bretonstone® into a product of prestige; it was already a product of quality - now more beautiful than ever.!
Bretonstone® Natura

Bretonstone® is a totally eco-friendly product, both in terms of the production process and the finished product; today even more so, as we use Biolenica® resins made using vegetable oils obtained from renewable sources.
Bretonstone® is one big family; every company producing Bretonstone® has helped make the name something special, to leave its mark on the market as a real original: Stone Italiana, Santa Margherita, Caesarstone, Technistone, Cosentino, Cambria, Seieffe, Quarella, Privilege, Silicalia, Hanwha, AKG, Dupont, Vicostone, Diresco, Falat, ZKM, Pokarna, Quartzforms, LG, Belenco, Daelim.
To fully understand the extent of the phenomenon, here are a few figures: the Bretonstone® sector was invented in Veneto and developed over the years. Today there are approximately 60 plants operating around the world, directly employing over 6,000 people and producing over 20,000,000 m2 of slabs a year.
What really stands out though, is the exponential number of jobs
Breton has created and continues to create all over the world: when Breton supplies a plant, this means developing a new industrial production factory, then there are resellers, operators who transform the slabs, and last but not least the distributor/final user (a company producing kitchens for example), not to mention sellers; it’s estimated that Bretonstone® has created work for tens of thousands of people all over the world.
Dubai airport terminal 3
Everyone has most likely admired and appreciated Bretonstone® works, without perhaps even knowing what exactly the material is (often simply called “Quartz”). 
Armani store
Today, a designer who wishes to create something special, innovative and of the highest quality, will choose this fine material, with the added bonus of it being in line with tradition: Bretonstone® - the bridge between past and future!Bretonstone® has been used in many airports (Dubai, London Heathrow, Amsterdam), 
Burj al arab hotel
Burj al arab hotel

shops (Giorgio Armani in New York, Prada in Dubai, Fendi, Ferrè, Diesel, Swatch, Montblanc), shopping centres (Gallerie Lafayette, Sunset Mall Dubai), hotels (like the Buji Al Arab in Dubai), schools, hospitals, residential complexes, churches, mosques; from Paris to the US, the Arabian states to China, Malaysia, Singapore, Russia, Senegal, Brazil and Australia, .
There's a little Italy everywhere in the world, and a little of the person who invented, believed in, created and distributed this innovative Italian material that lets architects make dreams come true: Sir Marcello Toncelli.

For INFO & Price of BRETONSTONE® plants write to
We’ll get back to you promptly.
Well, that’s all for today, thanks for your attention.
Sergio Prior 

Monday, 27 May 2013

Levibreton KFM - Polishing lines for marble strips

Polishing lines for marble strips: 

Many years ago Breton was the first company to present continuous polishing systems for marble, revolutionising the industry.
Breton with the new Levibreton KFM series confirms its leadership in polishing systems for marble by offering, as always, highly reliable and innovative technological solutions, guaranteeing constant and superior machine performance over time.
A Levibreton KFM to satisfy any polishing requirement
The Levibreton KFM are available in various configurations and with various fittings, and they can operate as individual units or can be integrated into a complete processing plant. They can be fitted with calibrating spindles or polishing spindles and the number of spindles mounted can vary depending on the Customer’s precise production requirements.
High-power and High-precision calibrating units
The calibrating spindles are mounted to a robust cast iron monolithic structure which practically eliminates vibrations generated when operating even during intensive work cycles. A recirculating ball screw assembly positions the diamond plate guaranteeing constant precision and performance reliability. This system also automatically raises the spindle in the event the conveyor belt shuts down preventing the diamond tool from excessively machining the workpiece, and then when restarted the spindle automatically returns to its preset machining depth.

The machining depth for each spindle is visualised on a digital display with a precision to hundredths. To guarantee such highprecision machining encoders detect and monitor the position of the spindle rather than the ball screw assembly which moves the spindle. The recirculating ball screw assembly system adopted for raising the spindle guarantees fast and precise spindle
movements without wear, unlike conventional trapezoidal screw systems which in emergency conditions only allow for controlling vertical positioning of the spindle and do not raise and lower spindle.
Dynamically balanced large diameter and dimensioned diamond tools combined with high-powered motors, ensure high-speed machining performance.
The diamond are fitted with a removable external crown that allows for quick diamond segment assembly and fitting.
High-performing honing-polishing units  
The honing-polishing units are result of a specific design which has led to achieving:
Greater rigidity and machining performance thanks to
- new design cast iron housings.
- increased motor power.
Greater reliability thanks to
- new lubrication channels in the shaft bushing.
- a new central water feeding system which flows in axis with the spindle, mounted in an elevated position preventing any build-up and deposits.
- new lifting and lowering cylinders with protected rod.
Easy maintenance thanks to
- centralised grease nipples on the front of the spindle.
- new self-adjusting thrust bearings.
- the new system for displaying consumption of abrasive material.
Greater and improved safety thanks to
- water feeding in axis with the spindle to avoid any leakage onto the internal components and external water flow deviation system in the event of overfeeding or blockage.
- sealed and protected commands.

High-performing honing-polishing backing plates
Each honing-polishing spindle is fitted with a special Breton new design abrasive holding plate. The pneumatic operating pressure can be adjusted utilising the two pistons provided which also raise the head in the event there is no workpiece.
These special abrasive holding plates have a 500 mm diameter, mount 8 abrasives and are fitted with an exclusive multidirectional shock absorbing system.
The entire assembly ensures perfect elasticity and a constant and optimal operating pressure resulting in a workpiece with a perfect and uniform polished finish right up to the edges, all with a minimal consumption of abrasive material.

Adjusting working width
The robust side guides which contain the workpiece to polish can be adjusted in width utilising the two manual handwheels one mounted at each end of the machine in an easily accessible position for the operator. The working width is then set utilising the keypad on the operator’s control panel.

P E R F E C T  P O L I S H E D  F I N I S H
 Fixed calibrating units and honing-polishing units mounted on mobile bridge for a perfect polished finish of any size workpiece
In all the various models of this machine the calibrating spindles are mounted to a robust cast iron monolithic structure integral to a fixed rigid bearing beam. This entire structure practically eliminates vibrations generated when operating even during intensive work cycles. The experience developed by Breton teaches us to be able guarantee a quality polished finish for any size workpiece, it is indispensable that the honingpolishing spindles are mobile and not fixed. This is why the honing-polishing units on all the models of this machine are mounted to a mobile bearing beam, designed with a special closed rectangular profile, which generates elevated moments of inertia and optimal bending and torsional rigidity.

The beam rests on two vertical structures that travel on amply dimensioned rectified and tempered roller sliding blocks enclosed in a oil bath, along cast iron bridges which house the ground and tempered travel ways.
The reciprocating movement of the beam is powered by a transmission shaft connected at each end to a rack and pinion assembly. The shaft in turn is driven by a powerful motor reducer unit mounted on the centreline and commanded by a frequency variator.

Safety protections
The Levibreton KFM machines are fitted with front sliding soundproofed safety panels of robust construction with an ABS and polyurethane sandwich structure, and are resistant to water and waste generated during machine operation. Protective rubber spray guards are fitted to the beam facing the abrasive backing plates “in line” with the workpiece to polish.

Controls and display
Analogical manometers with operating pressure regulators and the spindle cycle selector switches are positioned in correspondence to each honingpolishing unit above the front sliding protections, protected from humidity, and easily accessible to the operator.

Displays with a precision to hundredths and selector switches for vertical positioning of the spindles are mounted to the front of each calibrating group. An operator’s control panel with display is mounted to one of machine side panels.

The polishing machine for marble strips Levibreton KFM is available in 10 version:
- KFM 65/28
maximun workable width 650mm, 2 calibrating unit and 8 dressing units
- KFM 65/33
maximun workable width 650mm, 3 calibrating units and 3 dressing unit
- KFM 65/012,
maximun workable width 650mm, 12 dressing unit
- KFM 65/312,
maximun workable width 650mm, 2 calibrating units and 12 dressing unit
- KFM 65/014,
maximun workable width 650mm, 14 calibrating unit
- KFM 65/414,
maximun workable width 650mm, 4 calibrating units and 14 dressing unit
- KFM 100/312,
maximun workable width 1.000mm, 3 calibrating units and 12 dressing unit
- KFM 100/28,
maximun workable width 1.000mm, 2 calibrating units and 8 dressing unit
- KFM 100/012,
maximun workable width 1.000mm, 12 dressing unit
- KFM 100/014,
maximun workable width 1.000mm, 14 dressing unit.

Well, that’s all for today.
For more INFO and PRICE about Levibreton KFM write to
Sergio Prior

Wednesday, 8 May 2013

GOLDBRETON - The multi-wire machines for cutting granite blocks

Good morning,
Today I want to to talk about GoldBreton 2000.
The most complete range of multi-wire machines.
The product range includes machines with 71, 56, 40, 30 and 20 wires.
It is possible to choose machines holding diamond wires with a diameter of 6,3 mm that produce a greater number of slabs per block, or machines holding diamond wires with a diameter of 7,3 mm.
It is possible to choose machines cutting slabs with a fixed thickness of 20 or 30 mm, or machines cutting slabs with a variable thickness of 20 mm and over (20, 30, 40 mm…).
Breton diamond wire machines GOLDBRETON stand out for lower maintenance costs per square metre sawn and amazing handiness in being operated and serviced, in fact all the routine maintenance is usually carried out by the customer's technician alone. 
They feature a heavy-duty steel structure which is heat treated to ensure the required stiffness of the system and a top cutting precision
The special painting guarantees a high corrosion strength. 
Machines are provided with a NC programming and control system and a software with user-friendly operator's interface installed on a dedicated PC.
The machines being networked, Breton After Sale Service can log into the PC of the machine via internet for the remote monitoring of any possible malfunction
So, why don’t you request a quotation for a GOLDBRETON?
Write to 
Have a nice day
Sergio Prior

Monday, 6 May 2013

Levibreton KFT 3600 - Lines for polishing marble slabs

Nowadays, the Levibreton KFT 3600 polishing lines for marble are the best and most advanced solution for companies requiring high productions combined with low transformation costs.
Breton was the first company to develop the machines for the continuous polishing of marble slabs, revolutionizing the field.
Automation, production, user-friendliness, simple maintenance and low operating costs are absolutely familiar concepts to Breton who knew how to masterfully convey them in the tried and tested, world-famous Levibreton KFT 3600
The dressing-polishing spindle units feature a sturdy cast-iron casing ensuring maximum rigidity and a consequent high removal capacity of the abrasives; under the mechanical and technological viewpoint, they are a concentration of reliability, safety and simplified maintenance.
Spindle units are lifted by a couple of pistons with constantly protected rod.
The lubrication points are centralized in front of the spindle unit in order to simplify the routine maintenance operations.
The water feeding system is positioned over the spindle units with passage along the spindle axis so as to prevent any possible build-up of residue, and an ingenious system diverts water outside the spindle casing in case of over-supply or clogging.
Each spindle is equipped with a high-performance special Breton abrasive-holding plate with a diameter of 550mm, holding 9 abrasives, which ensure an extremely high removal capacity and work stability for a perfect and uniform polishing even up to the edges of the material.
The special Breton plates are equipped with an exclusive one-way shock-absorbing system ensuring the correct flexibility and a homogeneous and optimal working pressure.
This also results in a lower consumption of abrasives
The beam is built using a special design with box-type section in order to both contain weight and provide high rigidity.
Therefore, the spindle/beam assembly is very dynamic and enables to attain extremely rapid acceleration/deceleration ramps and a very high travel speed (up to 70 m/min)
The reciprocating movement of the beam is actuated by two motor reducers (one for the KFT 3600/08) attached at each end, mechanically synchronised and controlled by a single frequency variator.
Motion is transmitted by means of a pinion/rack system.
The beam working speed achieves 70 m/min

The table constitutes the supporting structure of the machine and is fabricated as a distortion-proof, arc welded steel, single-piece chassis.
The conveyor belt slides upon a thick steel table, milled as a single unit to assure perfect flatness

The beam rests on two shoulders moving along two sturdy, cast-iron supports, which house tempered, rectified and thick tracks with large diameter roller slides in an oil bath.
The sliding components are protected by stainless steel labyrinth seals

An optical reader memorizes the slab profile with 10x10 mm resolution, while a sonar reader memorizes its thickness. These two systems work without any contact with the material.
This system allows to automatically control the raising-lowering of the heads and guarantees both the self-adjustment of the spindle beam travel as to the width of the processed slabs and the automatic positioning of the frontal, anti-splash and sound-proof protection guards according to the slab thickness

Connected to both the control PC and the sonar sensor registering the thickness of each individual slab, this optional system performs the following functions:
- continuous, automatic monitoring of the abrasive consumption for each individual head, with video-messages and pre-alarm before the tool is completely consumed
- minimal raising of the heads at the entry/exit of slabs and subsequent rapid lowering guaranteeing a better polishing of the slab sides as well as a higher working speed
The water supply to the heads is by a common, large-diameter, PVC-made central piping, placed above the spindle units.
The water supply from the main pipe to the slabs passes vertically inside the shaft of the spindle unit.
With this system, when the machine is stopped, all the water inside the piping automatically flows out by gravity thus avoiding any possible stagnation and consequent build-up of solid residues inside the pipes. An ingenious system diverts water outside the spindle casing in case of overflowing or clogging, thus preventing excess water from coming into contact with the spindle internal components.
The electric/electronic plant is wired with the innovative “field-bus” technique. It is a simple, single cable delivering all the PC signals with digital transmission to the different control units installed on the machine.
With this state-of-the-art system, the signal transmission is safe and free from any interference, and the identification of possible failures is greatly simplified.
The electric plant connecting the stationary parts of the machine with the mobile beam is by a parallel sheathing system, which secures safer working conditions and a longer life of the cables.
All the electric/electronic equipment, including the PC installed on the machine, are of the commercial type and supplied by first-class world manufacturers so as to make easier both the technical assistance and the readiness of spare parts, virtually throughout the world.
The operator interface is simple and immediate, realised with a PC operating in a Windows environment, and is provided with touch-screen.
The major work processes are controlled, such as:
- speed of the machine conveyor and synchronism of the whole line, including loaders and connection roller conveyors.
- back-slipping correction on the anti-skid conveyor of badly-sawn, bent slabs, for both single slabs and packs of slabs
- beam movement (speed, customised programming of acceleration and deceleration ramps)
- continuous automatic monitoring of the abrasive consumption for each single head, with video-messages and pre-alarm before the tool is completely consumed
- possibility to “exclude” all, some or just one slab under processing, or even a portion of the slab (head, end, corner).

The Levibreton KFT 3600 is equipped with evolved software the assisted Internet connection with Breton service, which facilitates remote trouble-shooting and expedites solutions.
Furthermore, the PC gathers and processes the statistical data relating to the production and consumptions, such as:
- production statistics on partial periods, or on job orders, or per shifts, progressives, or accumulative (hours of machine switched on, in operation, in alarm, square meters processed, etc)
- tool wear statistics (per each individual head, square meters produced - at a given time - with the operating tool, square meters produced with the last replaced tool, etc.)
- diagnostics of machine condition, with video display of any alarm occurred;
- maintenance programming with alarm on the display when preventive maintenance has expired
- image file of the slabs processed (as they are memorised by the optical reader placed at the entrance of the machine)
Moreover, the PC control of all these data makes them readily available to other supervising or control PC, or data can be exported in “.txt” format files so as to be processed by any “office automation” application software (for instance, Word, Excel, etc.).

Analogical manometers with operating pressure regulators and the spindle cycle selector switches are positioned in correspondence to each honing-polishing unit over the front sliding  protections, protected from humidity, and easily accessible to the operator.  
An operator’s control panel with display touch-screen is mounted to one of machine side panels.

The Levibreton KFT 3600 machines are fitted with front sliding soundproofed safety panels of robust construction with an ABS and polyurethane sandwich structure, and are resistant to water and waste generated during machine operation.
Protective rubber spray guards are fitted to the beam facing the abrasive backing plates “in line” with the workpiece to polish.

LEVIBRETON KFT 3600 comes in three versions, with 8, 14 15 and 17 spindles which are driven by a 11 kW motor each and hold plates with diameter of 550 mm; each plate holds 9 abrasive bricks for maximum removal capacity
The version with 17 spindles, specially designed for the most demanding production requirements, is equipped with a halfway bridge installed after the 7th spindle that "separates" the dressing from the polishing section. The dressing section is therefore stiffer, more "aggressive" and, if desired, capable of holding calibrating spindles on the first positions. A high-flow washing unit is mounted under the halfway bridge to wash out the residue of the coarse abrasive grains before slabs are processed by the finer polishing grains.
Well, that’s all for today.
For more INFO about Levibreton KFT 3600 write to
Sergio Prior