Diamond wire saws help increase production in Turkish quarries

Speed ​​and safety are paramount in the marble industry. On the one hand, companies need to increase production so as not to be overtaken by competitors; on the other hand, they need to focus on safety and quality issues.

In this case, the cutting speed and cutting quality of the wire saw in the quarry become a key factor for the manufacturer to reduce costs. Turkey is the world's fourth largest exporter of natural stone, and Karmersan is the leader among Turkish marble suppliers. Karmersan was founded in 1993 with several quarries and processing plants in Turkey, including the Harmankaya quarry near Burdur town and the quarry in the southern part of Isparta, which were in 1997 and 2010 respectively. Started operations in the year.

Equipment is favored

According to Salih Kaya, executive chairman of Karmersan, the market for beige marble produced by local quarrying plants is in great demand, especially in the Chinese market. According to actual needs, Karmersan generally employs 400-500 workers and has a capacity of approximately 1.2 million square meters per year. To date, the company has a fleet of more than 50 units, including 12 SpeedCut diamond wire saws from Atlas Copco, which are the result of the production and production costs of the mine. A huge impact.

Karmersan introduced the SpeedCut diamond wire saw about two years ago, and the latter has now become a key factor in the company's commercial operations. Kaya said that speed and safety are the two most important factors in their initial choice of SpeedCut, and the device continues to bring a variety of surprises. He said: "This machine is easy to operate and can be parallel cut at a distance of 2 meters without repositioning. Its design is beautiful and functional. It is easy to set up and the track and machine can be lifted at the same time." Kaya also said that SpeedCut Another advantage is that the remote control unit has a Turkish option on the operating menu, which makes it easier for the operator to operate.

The device's rotary torque function setting also makes the job extremely easy. “Traditional cutting equipment usually relies on rope traction to move,” he explains. “And SpeedCut completely avoids this because it has excellent rotational torque. In addition, when the sensor senses that the rope is broken, the machine will Automatic shutdown to protect equipment and workers, and the machine automatically stops when it slides to the end of the track.

Reduced production costs

SpeedCut quickly demonstrated its strength to the field staff with its 3 times higher efficiency than other cutting machines in the stop – achieving 150-200 square meters of cutting at an average cutting speed of 25-30 square meters per hour. In the past two years, the capacity of the stope has increased from 1,500 tons/month to 10,000 tons/month. Although the initial investment in this equipment is relatively high compared to other similar equipment on the market, Kaya is convinced that its return on investment is higher. “This equipment has greatly improved our productivity and the cost has been significantly reduced, including labor and utilities, and we have done more with less equipment,” he said. In addition, it took 28 hours. The completed cutting operation can now be completed in 8-9 hours.

Kaya continued: “I always thought it was a good investment, so I always insisted on it and saw its outstanding performance – this device is three times more efficient than the equipment we used before.” “Not only productivity has increased. The quality of the product has also been improved, because the cut surface cut by SpeedCut is clean and flat. Now basically all of our cutting operations are done with SpeedCut, and I believe this equipment will soon be popular in the entire Turkish quarrying industry. ”

From a safety point of view, Kaya believes that SpeedCut is “armed in place” and that the built-in air filter keeps the inside of the unit clean. “In quarries, it’s important to keep electrical equipment clean and dust-free, and SpeedCut does it on its own.” Because of the sagging of the ropes, especially in large-scale horizontal cutting operations, conventional machines can cavitation or It is called "wolf forging". This requires re-cutting of the product and damage to the working edge of the lever chain knife.

Kaya went on to say: “The rope break is the biggest problem, but the SpeedCut system has a special protection. Because its work depends on the load on the rope, it will automatically stop if it is dangerous.”

Atlas? Esisan, a distributor of Copco stone equipment, is responsible for supporting and repairing the quarry and helping its training operators. Kaya is very pleased with the work of Esisan. “It is important for the operator to understand the equipment, and Esisan's training is not one-off. Every time we need it, Esisan will come to help us train our staff.”

Gu?rkan Burak Buyurgan, business line manager for open-pit rock drilling and exploration equipment at Atlas Copco Turkey, said: “In this industry, the modernization of equipment is essential. In addition to our SpeedCut diamond wire saws and marbles In addition to the new SpeedROC equipment developed by R&D, we are committed to providing consumers with the lowest total operating cost in the industry and will always strive to provide the most satisfactory service to our customers."

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