Roofed area prepared for the manufacture of cobblestones in different sizes (9/11; 4/6; 9/11-5) for road pavements as well as other blocks from cracked stones.
This area is divided into 4 sectors:
The roofed area has a length of 80m/262ft. and a width of 10m/32ft and houses 16 50-ton cube cutter machines with individual storage areas located underneath each of the machines.
The current stone cutting area comprises 2 pavilions, with a global covered area of 5000m2/53819sq.ft., and an additional cube prep area of 1000m2/10763 sq.ft.
The prep area is 40m/131ft wide by 25m/82ft long, has two traveling cranes– a 25-ton and a 35-ton – and its own single diamond wire for dimensional trimming of the blocks.
The prep area will be connected to a 35-ton gantry crane, to streamline stone block loading and conveyance
At the beginning of each pavilion is a Pellegrini multi-wire saw machine – one with 34 wires and the other with 40 wires – served by two loading cart lines.
The wire-saw machines can cut 20 to 30 mm slabs or multiples thereof.
The maximum allowed block size is 2200mm/86in wide by 3200mm/125in high.
The first pavilion has three additional 3-disk – 3500mm/137in, 1600mm/62in and 600mm/23in – machines for cutting and shaping, and a CNC (to enter production by the end of April 2018) for mausoleum and diverse statuary shaping.
Marlin has a calibration and pre-polishing line for all produced granite slabs comprising a 10-head Barsanti calibrator, 6 of which are used for calibration and the remaining 4 for pre-polishing tasks. All freshly cut slabs must undergo this process, after which they will proceed to the resign application line or directly to the polishing line, according to client requirements.
All resign application equipment has been purchased from Breton S.p.A. in November of 2017. The applied epoxy resin fills every crack in the slab, creating a shiny vitreous surface. Once hardened the slabs will become more compact and resistant.
All steps of the resign application process are automated, from the loading of the slabs to the final delivery to the processing line. The slabs are first dried in an oven and are then coated with resin along with a catalyst. In case of shapes that need special attention, the resin can be applied by hand. All items are then led into a vacuum chamber that will drive the resin deeper into the stone to better reinforce the material and go into a second oven the hardening process of the resin, called catalysis. These ovens can dry/harden up to 40 slabs at one time.
Once the resin has dried, the slabs can proceed to the polishing line.
Marlin offers several finishing options, which allow for diversified formats and textures: polished, honed, brushed, bush hammered, flamed and riven.
The company has two finishing lines: a standard polishing line2 and a textured finishing line. All shapes coming out of calibration and pre-polishing or resign application lines will undergo a final polishing procedure.
This line used a 19-head Breton Levibreton KG 2000 polisher for a high throughput. The first 4 heads will remove surface resign while the remaining will fine polish the stone.
After final polish, a four-head waxing unit applies a coating of wax to the surface of the slab. This protects the surface during storage and transportation.
The current processing cycle is two minutes per slab, or 1,800 square meters of material in a single shift. Overall, Cometti is equipped to process 240 slabs per day, with an average slab size of 7.5 square meters.
For textured finishing, such as bush hammered or flamed, we use equipment from Construal which has an hourly processing capacity of 20m2/215sq.ft. for flaming and of 12m2/129sq.ft. for bush-hammering. Maximum slab width is 1600mm/63in.
The 5-axis fine cutting machine has been manufactured by Construal.
The technical area includes facilities for fuel storage, electricity generators and air compressors, as well as the water treatment unit.
