Choosing a multi-wire cutting machine
Volume No.:
127 
Technological breakthroughs in the stone industry tend to be few and improvements in machinery performance are usually a gradual process. However, in recent years, the multi-wire machines suddenly seem to have become fashionable, and one gets the impression that every major manufacturer of block sawing machines has decided it must have a multi-wire machine in its range of different products to offer to the industry.
Actual sales in the market have not really reached serious levels so far, perhaps because the stone industry all over the world has just gone through a severe economic crisis and relatively little expansion in production capacity has taken place in this period. Another reason why sales have not really taken off so far in a big way could be that it is still a new technology and potential buyers are hesitating before making a bet on these machines.
The time has come, however, to highlight to the industry the different models that exist in the market. This magazine sent seven questions to different manufacturers and below we publish the replies of those who chose to answer these questions. No independent verification was done by us, we have simply reproduced the replies as sent to us.
BARSANTI, Italy
1.- Is your machine supported on 2 or 4 columns?
We manufacture both models:
2 columns: 16-20-30-40-60- wires
4 columns: 70-80-133 wires
2.- What tension system does your machine have: hydraulic, mechanical, other...?
The tensioning of each wire is hydraulically operated with a patented system called “dynamically compensated”.
3.- How is the deterioration and the performance of the wire controlled?
The machine has double and redundant systems to detect when a wire brakes and in the event to stop immediately the machine.
4.- How many wires are mounted on your machine, and why?
See N. 1.
5.- What is the average monthly production of the machine?
The average production is based on the number of wires installed and the type of materials processed. We can range from about 4.500 sqmt. per month with a 16 wires machine (MIRAGE 480) to an outstanding production of about 45.000 sqmt. and more with 133 wires machine (MIRAGE 4000).
6.- As an objective data, a) What is the average consumption of wire per sqm in Euros? b) What is the average consumption in maintenance in Euros per sqm?
The consumption of wire depends mainly by the manufacturer of the tool itself. We designed the machine in order to give less stress as possible on each wire and to control with as much as precise is possible the real force of tensioning in each wire and keep it consistent during the work. The result was achieved by a new patent tensioning system called: “dynamically compensated”. As far as the maintenance cost is concerned our design philosophy is based on the same way we are doing the traditional gang saws: strong, reliable machines. The average cost is 0,20 €/sqm.
7.- What characteristics allow your machine to obtain these consumption levels and what would you like to highlight about your machine?
Our MDW machine “MIRAGE” series comes from an innovative design after few years of testing various technical solutions. The results is a reliable operating machine, a real multi thickness slabs producing working unit. It is possible to cut any thickness starting from 2 cm. with a pitch of 10 mm, easily and fastly. Our 4 columns is the only working MDW with the advantage to have a closed structure that allows the installation of a relevant number of wires (up to 133). The passage of the closed loop wires through the structure is realised with a simple static mechanical system.
BM, Italy
1.- Is your machine supported on 2 or 4 columns?
4 columns.
2.- What tension system does your machine have: hydraulic, mechanical, other... ?
Hydraulic.
3.- How is the deterioration and the performance of the wire controlled?
We produce only the machine not the wire, customer is free to choose from any wire supplier.
4.- How many wires are mounted on your machine, and why?
Maximum 76, depends on the model and width of the machine.
5.- What is the average monthly production of the machine?
Working time: 10 hours per day.
Block dimensions: 3000x2000x2000 mm (3000 lenght)
Material hardness: 3 lvl (20 cm/h downfeed)
M2 / h: 0,2 m/h x 3 m = 0,6 (1 wire)
M2 / h: 0,6 m2/h x 76 = 45,6 (1 wire)
M2 / month: 45,6 x 10 h x 22 (days) =
10032,0 M2 / month
Produces around 456 sqm per hour. 1400/456 = 3,07 Kw per square meter.
6.- As an objective data,
a) What is the average consumption of wire per sqm in Euros?
6 Euro Class 3 (hardness), 8 Euro Class 4, 13 Euro Class 6
b) What is the average consumption in maintenance in Euros per sqm?
0,45 € x square meter.
7.- What characteristics allow your machine to obtain these consumption levels and what would you like to highlight about your machine?
The “KODIAK BM” is constructed on 4 columns. It means the roller-wheels where the wires are located are under strong tension and they are connected to 4 columns, not only 2. With a structure based on 2 columns, the tensioned set of diamond wires makes a big flexion to the machine frame, so when the tension is removed, they change the position and they would not get it back when they will be tensioned again. So the position of the wires before removing the tension is not the same position they have after giving the tension again. This movement provokes a defect on the surface of the slabs called line/step. With a 4 columns gang saw, this problem does not exist because the frame of the machine is much more rigid and when the tension of the wires is being removed, it does not affect the movement of the wires.
- Stroke of wire tensioning system: 400 mm BM. Bigger the capacity of stroke (stretching the wire) better and easier it is to keep the tension homogenous for all wires and also the wires last for a longer period, since the wires will last longer.
- Material of pulleys: Stainless steel BM
- Useful cut to size in width : up to 2400 mm
- Pulley bearing feature: BM uses standard bearing that one can find in any bearing Shop => Cheap maintenance. Other producer use special bearing built with characteristic suitable only for their machines so the Customer is obliged to buy directly from them. Cost of bearing is really very expensive, for each pulley (wheel) and could be about 2500 €.
- Easy change of bearing: with BM you can take out completely 80 wheels and change one bearing of each wheel in 4 hours.
- Entrance of the trolley: lateral or frontal according to customer request.
- A wire stock: you can also put more than 80 wires inside the machine and stock some laterally so you can use those in the following cut without open the machine and insert the new wires.
CO.FI.PLAST, Italy
1.- Is your machine supported on 2 or 4 columns?
2 columns.
2.- What tension system does your machine have: hydraulic, mechanical, other... ?
High pressure electro-pneumatic patented system.
3.- How is the deterioration and the performance of the wire controlled?
The deterioration and performance is controlled via software installed on the machines.
4.- How many wires are mounted on your machine, and why?
We mount from 8 to 80 wires. It depends on the width of the block you want to process and the sizes you want to cut.
5.- What is the average monthly production of the machine?
If cutting Class 3 materials, in average for a 30 wire machine the monthly production is 10000 sqm
6.- As an objective data, a) What is the average consumption of wire per sqm in Euros? b) What is the average consumption in maintenance in Euros per sqm?
On materials Classe 3, maintenance 0,5€/sqm, cost of wire 4€/sqm
7.- What characteristics allow your machine to obtain these consumption levels and what would you like to highlight about your machine?
These consumption levels are achievable thanks to our patented tensioning system which is very elastic thus increasing wire performance. Our machines are available either gantry or stationary and all model offer a patented variable thicknesses. Also our patented interchangeable rubber strip liners have helped decrease maintenance costs.
GASPARI MENOTTI, Italy
1.- Is your machine supported on 2 or 4 columns?
It is a machine of 2 columns, which thanks to an innovative structure system called Castillos de Corte, supports the axes the same manner as would a rigid machine of 4 columns, maintaining the advantages of flexibility in production and speed in the operations of substitution and change of wire.
2.- What tension system does your machine have: hydraulic, mechanical, other... ?
There is a hydraulic system of pre-tensioning of the whole block tensor and apart from this group system, each individual tensor of the wire is also hydraulic.
3.- How is the deterioration and the performance of the wire controlled?
The machine controls automatically with an electronic system installed in each one of the wires. This electronic system transmits the sizes to the control system of the general electric system wire by wire. Moreover, the deterioration of the wire should be controlled by a qualified operator in the beginning and the end of each cut.
4.- How many wires are mounted on your machine, and why?
Our machines are produced in fixed and variable versions with several sizes of useful cutting width, to satisfy every production demand.
700 Maximum number of wires 24.
1000 Maximum number of wires 34
1200. Maximum number of wires 40.
2000. Maximum number of wires 68
5.- What is the average monthly production of the machine?
Our machine of 68 wires produces an average of 12000 sqm of slabs per month.
6.- As an objective data, a) What is the average consumption of wire per sqm in Euros? b) What is the average consumption in maintenance in Euros per sqm?
The wire costs between 4.5 and 5 Euros per sq m, if we consider a quality wire. For maintenance we consider an incidence of 0.5 Euros per sqm excluding labour cost.
7.- What characteristics allow your machine to obtain these consumption levels and what would you like to highlight about your machine?
The characteristics that allow for the maintenance incidence to be less than 0.5 Euros/sq m in our machines are:
1 Linings. All the plastic or synthetic rubber coverings are interchangeable without need for dismounting the pulleys or drums.
2 Tension system and control of lengthening and direction of wire-The pretensioning system GASPARI MENOTTI displaces the whole set of pulleys to a point close to the optimum tension of the wire. Later, oleodynamic pistons totally protected and with detectors of displacement in its interior, move the tensor pulleys guided by cylinders of big diameter, also protected, the wire tensioned and controlling its lengthening and direction.
This allows us to: •Reduce to the minimum the incidences in the tension system. •Obtain a reliable system in the control and lengthening of the wire. •Tension and de-tension the machine at great speed for changing the wires or for changing the thickness of the cut.
3 Rollers. SKF, in collaboration with GASPARI MENOTTI has developed special rollers with greasing for life for the GASPARI MENOTTI machines and these rollers of low cost (less than 500 Euros) are mounted on all the pulleys, drums, etc. of the machine (one must take into account that the pulleys of the machines exceed the diameter of 70 cm). These rollers are guaranteed by GASPARI MENOTTI during 5 years though in the tests realised till now SKF indicates that its duration will be more than 8 years.
NODOSAFER, Spain
1.- Is your machine supported on 2 or 4 columns?
The multi-wire machine of NODOSAFER is supported on 4 columns.
2.- What tension system does your machine have: hydraulic, mechanical, other... ?
The tension system is hydraulic.
3.- How is the deterioration and the performance of the wire controlled?
The way by which the machine controls the deterioration and the performance of the wore is by achieving a good rotation.
4.- How many wires are mounted on your machine, and why?
Our machine has 65 wires with the aim of being able to cut a block at one go.
5.- What is the average monthly production of the machine?
Depending on the dimensions of the blocks and the strength of the material, the average production oscillates between 14000 and 20000 sqm per month.
6.- As an objective data, a) What is the average consumption of wire per sqm in Euros? b) What is the average consumption in maintenance in Euros per sqm?
The consumption of wire depends on the manufacturer of the wire, of the order of 4.5 Euros per sqm.
7.- What characteristics allow your machine to obtain these consumption levels and what would you like to highlight about your machine?
The characteristic of our machine that stands out the most is its robustness since it is supported on 4 columns and guided by means of precision guides so that we achieve a perfect vertical cut. Moreover, it has a tension system of high sensibility and precision that increases the duration of the wire.
PEDRINI, Italy
1.- Is your machine supported on 2 or 4 columns?
The structure of the multiwire Pedrini Jupiter GS200-W64 is composed of two columns strongly fixed to foundations and one connecting “Arco” structure that have been built with wide closed section in large thickness normalized steelwork. All the structural parts have undergone structural checks in accordance with FEM (Finite Elements Methods).
2.- What tension system does your machine have: hydraulic, mechanical, other... ?
The individual tensioning action of the wires is powered through one oleodynamic pump.
A first system performs the large displacement necessary for diamond wires replacement and thickness change, whilst a second system holds programmed tension equal on each wire and balance wire elongation during the cut.
3.- How is the deterioration and the performance of the wire controlled?
The position of the tensioning pulley of each wire is constantly controlled by means of transonar. The machine is able to check the eventual excessive stretching of each wire. The downfeed and the cutting speed, the power consumption are displayed on the monitor.
4.- How many wires are mounted on your machine, and why?
64 wires can be installed on the machine, to produce slabs with thickness 2 cm, for a total coverage of 1.8 m. The machine is flexible: it can produce any thickness by appropriately placing the wires into the grooves guide.
5.- What is the average monthly production of the machine?
Granite slabs thickness 2 cm: 13750 m2/month. Granite slabs thickness 3 cm: 10000 m2/month.
6.- As an objective data,
a) What is the average consumption of wire per sqm in Euros?
5 Euro/sqm
b) What is the average consumption in maintenance in Euros per sqm?
0,5 Euro/sqm
7.- What characteristics allow your machine to obtain these consumption levels and what would you like to highlight about your machine?
It is precise: it represents the perfect synthesis between structural rigidity, dynamic balancing and accuracy in displacing and sliding.
It's a hi – tech machine: it has recourse to exclusive and advanced patents which make it unique in its line.
It's reliable: it proposes simple technical solutions, without using delicate or risky mechanical elements.
It's functional: it is designed and manufactured to optimize the yield diamond tool of the.
It's versatile: it is available in the models with 8, 16, 32, 40, 56 and 64 wires, therefore it is suitable for any production requirement.
It's flexible: it allows the simultaneous cutting of slabs with different thickness, from 2-10 cm.
It's rational: thanks to a “user-friendly” interfaces it facilitates the operators to manage the diamond tool and the machine as well.
SIMEC, Italy
1.- Is your machine supported on 2 or 4 columns?
Machine with a 4-column structure with cutting system placed at a fixed dimension.
2.- What tension system does your machine have: hydraulic, mechanical, other... ?
System of pneumatic tensioning, independent for every wire, with electronic control of tension (patented).
3.- How is the deterioration and the performance of the wire controlled?
The control panel, equipped with a wide colour touch screen display allows the control of every operation accomplished by the machine and the supervision of all the operative values:
- tension of every single wire
- down feed speed
- current absorption
- water consumption
- production statistics and much more
On all of SIMEC’s last-generation machines, a remote diagnosis system is available, made through a net connection (optional). The machine has an Ethernet input through which it can be connected to an adsl line or to the company net with internet access; in such a way it can be controlled by SIMEC’s technicians who can carry out diagnosis or assistance interventions in remote control. In this way the machine stops are reduced to a minimum, guaranteeing great intervention rapidity.
4.- How many wires are mounted on your machine, and why?
70 wires; SIMEC considers it essential to cut a block into a work shift.
5.- What is the average monthly production of the machine?
A full block in 7/8 hours (granite class 3).
7.- What characteristics allow your machine to obtain these consumption levels and what would you like to highlight about your machine?
The SIMECWIRE gangsaws have 4 columns with a cutting system placed at a fixed dimension and a block lifting platform (SIMEC patent) capable of housing up to 70 diamond wires. The choice of the 4 columns has been fundamental in this project and allowed to put the drums around which the diamond wire turns in a fixed position, thus assuring rigidity and absence of vibrations, unattainable by other solutions. The wide cutting space and the high number of wires that can be installed, allows to saw one entire standard block or two small blocks in one go. Possibility to change the cutting thickness from 2 to 3 cm and more.