Franken-Schotter – inaugurates a new industrial plant

On October 12th, Franken-Schotter gave a big party for launching the new factory in Petersbuch. In addition to the 340 employees and their families, the management and the shareholders welcomed also many distinguished guests, among them Joachim Güter, the president of the German natural stone industrial association. In his speech, he stressed the natural stone sustainability and cheapness.

New jobs creation The regional governor Anton Martin Knapp and the mayor Martin Heiss congratulated Franken-Schotter for his close bond with the region and the creation of 15 new jobs so far - others positions will be created. Knapp congratulated him saying that it is impressive the management courage and foresight for creating the largest European company in the stone processing industry. The Italian company, Breton SpA, provided all the stone machining centres to the new factory. Breton President, Luca Toncelli, attended the event.

100 meters long resin line
The company has so far invested 9 million € in the new industrial plant, 5 additional millions € are estimated for the second part of the project as well as for the construction of offices and buildings for the employees. The Petersbuch new plants heart is a line which gives resin treatment to 100 meters long natural stone slabs. "We provide our customers with 99.98% natural limestone and that’s why we define it as natural stone," says the CEO Hans-Jochen Zech. 

Environmental friendly and sustainable 
In the design of the new plant, the engineers gave great value to high economic and environmental standards. The rainwater, for example, is collected in underground tanks, production and power lines are equipped with electric motors and drives belonging to the highest energy efficiency class. It employs new technologies for better use the material and, for the same amount of material to sell, you'll save as much as 20% of the extracted raw blocks. Franken-Schotter extracts limestone, Dietfurt dolomite and Jura limestone.

Machines live demos 
After the official party, the people attending the event had the opportunity to see the machining centres on work and in that way they got an idea of the impressive technique and all the available possibilities for working the stone with modern technologies. 

(Article selected from Natursteinonline.de magazine)
It 's all for today
By-bySergio Prior

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breton resin line, breton stone machinery, natural limestone

Ortobreton 4EG - Multiblade cutting system for granite block with independent strip extractor

Ortobreton 4EG - portal block saw

Maximum rigidity to increase performances and minimise running costs 

Portal machine 

The circular blades are positioned on the machining area by shifting the block platform. 

Superframe structure

Two columns on each side of the spindle support beam provide greater rigidity.

The improved geometry minimises vibrations 

The portal block saw is the ideal solution for limiting the vibrations. Each circular blade works in ideal conditions and cutting accuracy is excellent.  

4EG block saws enhance the portal layout by means of two columns on either side of the machine. 

The portal structure enables the horizontal blade to be easily incorporated into the solid structure of the machine. The horizontal blade detaches the strips whilst the vertical ones operate.

SUPERFRAME structure     
The 4EG block saws are a real point of reference as to rigidity and stability of the cutting system.

The superframe structure provides the solidity required by a blade pack wider than one meter.

Each end of the spindle beam is rigidly fixed to two columns.

The structure acts against twisting of the spindle beam even when thrusts have a transversal component.

Vertical movement of the beam is provided by a reduction gear that transmits movement to the four angular transmissions connected to the four screws so as to ensure precise positioning.

Cutting is thus very precise, even in critical conditions, e.g. when only one side of the blade pack is working.

Unit for integrated horizontal cutting     
In the Ortobreton 4EG SFO block saws, the horizontal cutting unit is connected to the main structure of the machine but is independent from the vertical blades: this allows the unit to remove the strips while vertical blades cut the next series.                             

In this way the machine is always running, thereby ensuring greater productivity.

The horizontal blade unit slides on the two front columns and has very precise movements.  

The horizontal blade works in synchronism with the automatic vacuum unloader that moves to the right position so as to pick up and support the strip before it has been completely detached. 

The overhead structure of the unloader minimises the space occupied on the ground and enables very rapid cycles that are much less than the time required to detach the strip.

A machine designed to minimise running costs 

The running costs of a block saw are mainly due to the cost of diamond tools. The annual expense for tools may be as great as the amount invested in the machine. 

Wear of the diamond tools depends, besides on the rigidity of the machine structure, also on how the spindle carriage travels. In the 4EG model, an asynchronous motor controlled by an inverter that actuates a pair of parallel racks meshed to two pinions, moves the spindle-holding carriage. 

A dynamically balanced, large-sized spindle shaft performs the blade rotation.  In the 4EG 1100 SFO, the diameter is 210 mm and the moment of inertia is almost four times that of a shaft with diameter of 150 mm. This great moment of inertia means that the spindle shaft flexion is minimal even under heavy-duty conditions with 60 blades applied.

The unit for moving the platform into the machining area 

A rugged steel guard protects the screw in an oil bath that conveys the platform to the machining area. 

A labyrinth seal prevents water from coming into contact with the screw, which is moved by an inverter-driven motor. 

The platform reaches its working position with great precision by running on a flat and a prismatic rail. 

Management system with personal computer in Windows environment

The work of the block saw must be programmed very carefully. To increase the operator’s concentration, the machine is managed by a personal computer where a user-friendly software facilitates all operations. 

The data on block dimensions can be easily acquired by positioning the machine’s work axes using the palmtop keypad.

The personal computer can be connected to the Breton remote assistance service, which can rapidly acquire the information on machine status in order to carry out a rapid diagnosis and if necessary proceed directly with a software operation. 

Numberless statistics regarding operating time and tool duration can be processed. The programme also warns the operator when it is necessary to carry out a scheduled maintenance job.

Here you can find technical data about cutting granite block machine Ortobreton 4EG.

I'm done for today. I hope i haven't bored you.
Click here for request or other INFO.
By-by
Sergio Prior

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breton stone machinery, cutting block granite, ortobreton 4eg, portal cutting blocks granite, saw granite blocks

Breton high-duty resin-treating plant

Since 1991 SIRMERSAN Marble Industry Inc. (Cinnah Cad. 46/3, Cankaya, Ankara, Turkey) has been producing and exporting top quality marble blocks, slabs and tiles and has now become one of the largest producers of travertine with 3 quarries and 2 production sites.
In 2002, SIRMERSAN began marketing a prestigious beige marble quarried in Yesilova with the brand "White Pearl".SIRMERSAN factory is located in Denizli, the Turkish heart of marble quarrying.

A Breton automatic cutting line for marble and/or travertine slabs will start operating in September 2013. A scanner reading the slab surface and software for cut optimization (suitable even for slabs with irregular surface and inner defects) will be installed at the forepart of the line.
The line will produce tiles, strips and panels with the desired dimensions with top efficiency and precision.

A new Breton slab resin-treating plant will start producing in February 2014: it is indeed the plant with the highest production capacity ever installed in the world, capable of processing one net-reinforced slab which is resin-treated on both sides every 55 seconds.

This mega plant is fully automatic and includes six 40-level kilns, a vacuum chamber and two stations for resin mixing and spraying.

The following are its distinguishing features:
1. slabs are directly loaded from the gangsaw trolley and it is possible to handle them in the "diamond-match" pattern
2. double drying and catalysis kilns in order to ensure a cycle time of 55 seconds/slab (net-reinforced on one face and resin-treated on both faces).
3. the resin-treating and netting operations are performed automatically
4. user-friendly operational software on colour touch-screen
5. plant with a reduced encumbrance: approx. 700 m2.
Well, that’s all for today.

By-by

Sergio Prior

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breton stone machinery, cutting line marble granite, resin plant marble granite slabs

Happy Birthay Breton! 1963-2013

Good morning,
This video shows some of the most important events occurred in Breton and throughout the world during the last 50 years.
Enjoy the movie

Well, that’s all for today.

By-by
Sergio Prior

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breton multiwire cutting granite blocks, breton polishing machine, breton stone machinery, bridge saw cnc

Breton NATURAL STONE machinery - Istitutional video

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breton spa, breton stone machinery, levibreton, multiwire machines

Levibreton KFT 3600 - Lines for polishing marble slabs

LEVIBRETON KFT 3600: A PRODUCTION PHILOSOPHY 
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. 

HIGH-REMOVAL DRESSING/POLISHING SPINDLE UNITS
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.

 
SPECIAL BRETON PLATES
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
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 MOTORIZATION OF THE SPINDLE-HOLDING BEAM
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
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 SLIDING SUPPORTS
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. 

THE SLAB PROFILE AND THICKNESS READERS 
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.
THE AUTOMATIC CONTROL OF THE ABRASIVE CONSUMPTION
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 PLANT
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
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. PROGRAMMING
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). 

TELEDIAGNOSIS 
The Levibreton KFT 3600 is equipped with evolved software the assisted Internet connection with Breton service, which facilitates remote trouble-shooting and expedites solutions.
STATISTICS
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.).

CONTROLS AND DISPLAY

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.

SAFETY PROTECTIONS

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 mail@breton.it
By-by
Sergio Prior

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breton marble machines, breton stone machinery, levibreton KFT 3600, polishing marble lines

Polishing line Levibreton KG4000 PLUS for granite slabs

Hello,
Today I’d like to talk about granite polishing.

I visited the factory of CERESER MARMI in Rivoli Veronese a few days ago.
Mr. Domenico Cereser took over the company management after his father Gianluigi, the founder. CERESER MARMI, established in 1965, is specialized in the processing of marble and granite slabs.

Here Breton installed a line “Levibreton KG 4000 PLUS” for granite slab polishing, which mainly consists of:

1 – Slab automatic loader mod. JOT

2 - Laser detector of the slab thickness

The thickness of the slab feeding the polishing machine is sensed by a special laser detector that checks if it conforms to the expected thickness; if not, the slab is excluded and it is calibrated outside the line (if its thickness is higher) or rejected (if its thickness is lower).

Whenever the slab does not fall within the pre-set parameters, an audible and visual alarm turns on at the end of the line so as to forewarn the operator who can handle the material unloading accordingly. 

3 - Slab polishing machine Levibreton KG4000PLUS/19

4 - Slab waxing machine with 4 spindles mod. CG/200/4

5 - Unit for the application of a polyester film mod. APLE 20/35
6 - Slab automatic offloader mod. JOT

TYPE OF MATERIAL: natural granite, reinforced with net+resin.
We will install very soon IMAGEPLUS, a Breton system to take, file and code extra high resolution photos of natural and engineered stone slabs, and label the slabs as well.
Therefore, within a few minutes, your own archive with true colour, extra high resolution photos of all the stored slabs will be available.
We will also install APP 22/35, an automatic unit placed before the slab automatic offloader, at the end of the polishing line, which is used to apply points or streaks of thermoplastic polymer on the slab polished face.  The function of the points/streaks of polymer (whose number, pitch and shape can be pre-set at will) is to protect the polished face of slabs whenever they are stored and handled arranged in a stack.
Well, that’s all for today.
By-by
Sergio Prior 

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breton stone machinery, levibreton kg4000 plus, polishing granite slabs