Levibreton KFG 3600 - High production lines for polishing marble slabs

Levibreton KFG 3600 a project that has been a striking industrial success for both Breton, the producer, and the customers.

The NEW Levibreton KFG 3600, combining ground-breaking concepts with well-tried solutions, is the evolution of the renowned several models of KFG 3000 that were tested wherever in the world marble is processed.

LEVIBRETON  KFG 3600: 
a productive philosophy

Nowadays, the Levibreton KFG 3600 polishing lines for marble are the most valued and leading-edge answer for companies requiring high productivity combined with low conversion costs.
Breton was the first to develop the continuous polishing machines for marble slabs, thus bringing a revolution in the field. Today concepts such as automation, productivity, user-friendliness, easy care and low operating costs are absolutely familiar to Breton who knew how applying them masterly to the superlative Levibreton KFG 3600.

LEVIBRETON KFG

A 30-YEAR WORLDWIDE SUCCESS

The story goes on with the newmarble polishing machine Levibreton KFG 3600

Honing-polishing units

The new design of the aluminium-alloy honing-polishing units allows their weight to be reduced and their stiffness increased.
The spindle raising-lowering system is perfectly balanced and features two pistons with protected internal rods. The abrasive holding plates are raised and lowered in fractions of a second, with minimal lifting from the surface of the slab, thus enabling the slab edges to be polished better and the operating speed to be increased.
The analogue manometers displaying the pressure of each single abrasive holding plate as well as the manual pressure regulators are placed close to each spindle unit on the machine front, just above the sliding doors.

Special Breton plates

Each spindle unit of polishing machine 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.
Besides giving an unequalled polish, this also results in a lower consumption of abrasives.

Beam

The arc-welded steel beam has a special design with box-type section in order to reduce weight and provide high stiffness. The spindle/beam assembly is thus very light and dynamic and enables fast acceleration/deceleration ramps and a travel speed up to 70 m/min.

Beam drive

The beam is actuated by two brushless-type motors at each end of the beam, which are mechanically synchronized so as to ensure a high dynamic movement without stressing the mechanical components.
Motion is transmitted by means of a rack and pinion mechanism: the simplest, most efficient and reliable system. Beam working speed reaches 70 m/min. When the beam slows down, “energy recovery” drives supply energy to the electricity grid, thus saving energy.

Supporting structure and bench

The supporting structure is a distortion-proof, arc-welded steel monobloc provided with 12 sturdy supporting legs.
The conveyor belt slides upon a thick steel table, milled as a single unit to ensure perfect flatness.
The conveyor belt is driven by brushless-type motor to guarantee better control of the feed speed.

Beam sliding supports

The beam is fixed to two shoulders sliding along two sturdy, cast-iron supports, which house hardened, ground and thick tracks with large diameter roller slides in an oil bath, and a micro pinion. The slideways are protected by stainless steel labyrinth guards.

Slab profile and thickness readers

A photoelectric barrier reader detects the slab profile with 10x10 mm resolution while a sonar reader senses its thickness. This system can accurately read even slabs with a smooth surface (such as slabs that have already been polished or resin-treated). The system allows the head lifting-lowering to be controlled automatically, ensures the beam travel self-adjustment to the width of the slabs and guarantees that the front, anti-splash and sound-proof protection guards are positioned automatically to match the thickness of the slabs.

The water plant

Water flows vertically from the main pipe to the slabs 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.

Automatic control of abrasives consumption

This system monitors continuously the abrasive consumption of each single head, sending video advice notes and warning signals before the tool is completely worn out.
It also ensures the minimal lifting of the abrasive holding plates at the slab entrance/exit and their subsequent rapid descent to permit better polishing of the edges and higher operating speed.
Water is supplied to the abrasive holding plates through a common, large-diameter, PVC central piping, placed above the spindle units.

Electric and electronic plant

The electric and electronic plant is wired with the “field-bus” technique that transmits digitally all the PC signals through a single cable to the different control units installed on the machine.
Signal transmission is safe and the identification of possible failures is greatly simplified.
The stationary part of the machine is electrically connected to the mobile beam by a parallel sheathing system ensuring safer working conditions and a longer cable life.
All the electric and electronic equipment, including the PC installed on the machine, is supplied by first-class international manufacturers so as to make technical assistance easier and spare parts readily available virtually throughout the world.

Automatic centralized lubrication system

A centralized system, consisting of a grease reservoir, electrically controlled pump, sequential distributors and flexible high-pressure pipes, automatically lubricates both the spindle units and the other moving components of the machine. The master distributors are equipped with overpressure indicators enabling to easily locate any possible clogging.

Slab cleaning

A rubber wiper fixed at the back of the machine removes water from the slab surface.
A pneumatically controlled spindle unit, integral with the beam and equipped with a brush, cleans the slabs as they pass though, once they are polished.

Guards, ergonomics and all parameters under control

A control board provided with analogue pressure display, manual pressure regulator and abrasive holding plate raising/lowering selector is installed on the top part, in an ergonomic and safe position, far from water and moisture and close to each single spindle unit. The abrasive holding plate raising/lowering selector completes the board.
The accident-prevention, sound-deadening, sliding, frontal panels have a sandwich-like structure. Panels are made of ABS and polyurethane, are heavy-duty and resistant to water and process wastes.
Sound-deadening splash guards with a stainless steel sandwich-type structure are installed on the beam, in front of the abrasive holding plates, at the same level as the slab. The positioning of the splash guards is motorized and automatic in order to match the slab thickness and simplify the change of abrasives.

Management and programming

The colour touch-screen video and advanced, user-friendly processing software enables the main processing functions to be managed, including:
•    possibility of storing (and recalling) different work programs for various types of material;
•    speed of the conveyor and synchronization of the whole line, including loaders and connection roller conveyors;
•    beam movement (speed and customized programming of acceleration and deceleration ramps);
•    operating pressure of each single abrasive holding plate;
•    interpolation of the operating pressure of each single abrasive holding plate with the precise position of the beam thanks to metering valves;
•    back-slipping correction of badly-sawn, bent slabs on the anti-skid conveyor, for both single slabs and packs of slabs;
•    automatic, non-stop monitoring of the abrasive consumption for each single plate, with video advice notes and warning signals before the tool is completely worn out;
•    possibility of disabling from the process all, some or one single slab, or even a portion of slab (head, end, corner).

Remote diagnosis

Levibreton KFG 3600 is provided with an advanced software in order to be networked with Breton service, thus facilitating remote trouble-shooting and expediting solutions.

Statistics

Furthermore, the PC gathers and organizes statistical data relating to production and consumption, such as:
•    production statistics based on partial periods, or per job order, per working shift, progressive or accumulative (hours of machine switched on, in operation, in alarm, square meters processed…);
•    tool wear statistics (per single abrasive holding plate, square metres produced in a certain period while the tool is working, square metres produced with the last tool replaced…);
•    diagnostics of the machine condition, with video display of any alarm occurred;
•    maintenance programming with video displayed alarm when preventive maintenance has expired;
•    file of processed slabs (as they are detected by the reader installed at the front part of the machine)

For more INFO and PRICE about Levibreton KFG 3600 write to mail@breton.it.
Well, that’s all for today.

By-by
Sergio Prior

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breton marble machines, levibreton kfg 3600, marble polishing machine, polishing lines marble, polishing marble slab

The «tarolo» is no longer a problem, thanks to this super Breton machine

The «tarolo» is no longer a problem, thanks to the Maxi super machine bought by SAGEVAN: today Michelangelo wouldn't have to fill the veins in his David with white "stucco"

FIGHTING BACK AGAINST THE CRISIS: THE FLAW IN MARBLE CORRECTED BY AN AUTOMATED BRETON MARBLE POLISHING MACHINE

by GUIDO BACCICALUPI

The veins called “TAROLI” in marble that drove even Michelangelo mad as he had to fill the block of marble used for the sculpture of David with lime mortar, are no longer a problem for our quarries thanks to a new super machine. 

SAGEVAN a Gemignani and Vanelli company and one of the biggest in the Carrara district, raised the bar on quality by investing in this “jewel” in the Breton crown, which not only doubles production output, but also means a remarkable increase in the quality of marble slabs used in coverings and architecture. 

The machine, worth almost 2 million euros, was unveiled Friday evening at the new SAGEVAN works in the Asi (ex Coke) area located in viale Zaccagna (Carrara), in a ceremony attended by the Mayor of Carrara Angelo Zubbani (who remarked “a wave of optimism in these difficult times”), the Deputy Mayor Andrea Vannucci, the President of the Industrialists Association Giuseppe Baccioli and the Provincial Councillor for Productive Activities Paolo Baldini. 

A well-polished works where you can't help but notice this giant “masterpiece” of engineering, fully automated with the operator controlling the resin application and polishing from the console. Like a DJ at the controls of a disco. Great progress has been made also in terms of safety: when the marble slabs are being polished no one can approach the machine and a photocell detects any intrusions, causing the system to stop. 

“We went against the general trend — explains architect Egidio Marino, one of the owners of the company — and in a time of crisis we invested considerable resources in a machine  that solves one of the biggest problems with marble slabs, the so-called "tarolo", a small cavity that decreases the value of the material because if the veins aren't treated properly in time they absorb dirt and the surface will become darker. This machine uses sophisticated technology based also on a UV oven catalysation system. A protective film is applied to the surface with the "taroli" then the slab is polished to perfection."

SAGEVAN employing around thirty people, is in the Calocara district where it gets and processes its marble: “Our customers must come and see the products — adds Marino — added value for the local product. We've installed a digital system to take high-definition photographs of our materials." “We just finished supplying White marble slabs for covering a skyscraper in Central Park, right in the heart of New York. Thanks to architecture, our marbles are more and more popular — emphasizes Manrico Gemignani, one of the company shareholders — but you have to offer a product of the very highest quality." The new machine can produce up to 1,000 square meters of slabs per day. 

SAGEVAN is specialized in the production of slabs made of the typical white and “coloured” marble obtained in the Calocara A-102 Quarry: marbles of a high ornamental value such as the Statuario Venato, Calacatta, Paonazzo and Paonazzetto as well as marbles with excellent technical-aesthetic qualities such as the Statuarietto, Venatino, Bardiglio and Carrara White.

Written by La nazione Massa Carrara  
06.10.2012 

Sergio Prior

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New Levibreton KFT line for polishing marble

Good morning,
Today I’d like to show you a new polishing line for marble slabs we recently installed by one of our customers, SA.GE.VAN of Avenza - Carrara (Italy).

This line has a production capacity of approx. 1.200 m2 per shift and polishes marble slabs with a maximum size of 2050x3300 mm.
Once loaded on the line, the slab is first trimmed crosswise (leading/trailing end) and then lengthwise.

The slab is then polished on the Levibreton KFT with 8 spindles, dried and heated to remove any residual humidity.
At this point, the slab is automatically filled and exposed to UV rays so that the filler gelates and shrinks allowing for the manual addition of some more filler.

The filler is catalyzed under the kiln and the Levibreton KFT with 14 spindles completes the slab polishing process.
The dried slab is conveyed to the automatic waxing and application of a polyethylene sheet, to be lastly unloaded on the A-frame.

Automatic slab loader

Longitudinal trimming machine

Polishing machine Levibreton KFT with 8 spindles

Cleaning unit

Radiant units

Automatic void filling machine

Slab filling

Polishing machine Levibreton KFT with 14 spindles

Automatic waxing machine

Automatic equipment to apply a protective film

 Special comb-shaped conveyor

Automatic slab unloader

Click here for more INFO.
By-by
Sergio Prior 

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breton marble machines, breton polishing machine, levibreton kft, marble slabs plant, polishing marble lines, polishing marble slab

NEW Breton polishers Levibreton KFG for marble

Hello,

Can you tell me what’s behind this mirror-polished slab?

You can hardly see it: it’s the new high performance polisher Levibreton KFG for marble.

 

This polishing line is installed at Stocchero Attilio's, in Volargne (VR),  one of our long-time customers who is very satisfied with the two new Levibreton KFG.

The first Levibreton KFG has 9 spindles and dresses marble slabs.

The maximum speed of the mobile beam is no less than 70 metres/minute.

Deriving from the design of the renowned polisher Levibreton KG for granite, which has a heavy-duty structure, specially dimensioned for granite, Levibreton KFG boasts a very high productivity.

The second Levibreton KFG has 15 spindles and polishes marble slabs to perfection.

The new standard Levibreton KFG can be supplied with 11 and 18 spindles.

Click here for more INFO
By-by
Sergio Prior
 

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breton machines, breton polishing machine, levibreton, levibreton kfg, machine polish marble, polishing marble slab