Basalt Block Cutting Machine in Turkey

TOKSEL TAURUS GANGSAW MACHINE
Taurus-80 has a special design that transforms marble, beige, basalt blocks and rubble into slabs with minimal waste.
Corrosion which shortens the life span of machines due to water and dirt, is prevented via hot-dip galvanizing. 400-500°C hot-dip galvanize reaches to every spot that regular dye might fail to cover and lengthens the life span of the machine up to 100-120 years by preventing corrosion. Two block cars and a transfer car are hot-dip galvanized as well.
A rigid, vibration free structure is the well-known key for a precise cut. Connecting rods,
eccentrics and bearings are made of monoblock steel casting. This feature promises
precise cut. It is proven with an interesting test which is recognized as a challenge in stone
industry: When a coin is placed vertically on a high point of a gangsaw where it is likely
to vibrate the most, it stays stable even during fastest cutting mode.
Although swinging system is proven to be superior to other systems worldwide, monoblock cast steel swing arms are unique to Toksel. Connecting rods which are usually made of weld platinum, are also made of monoblock cast steel in Taurus-80.
Another feature that provides precise cutting is PLC system which offers various modes for
cutting. For instance you can produce slabs from smaller unshapely rocks and rubbles with
minimum wastage in sensitive mode.
To prevent tremendous damages due to cracks in stone blocks, Taurus-80 quickly stops thanks to switches in the front and back. Toksel is the first to use 132 kw. inverters to make this emergency stop and a smooth start possible.
When it comes to energy saving, besides the advantage of the friction-free swinging system, Toksel added high efficiency IE3 motors.
Unlike other gangsaw machines, Taurus-80 has automatic lubrication system instead of manual lubrication. Since the water valves are usually located inconveniently on the top of the machines, staff often forget to shut it off. Another admirable feature of Taurus-80 is automatic water valve.

Karann Multi Wire Saw Machine
Our different machine models between 10-36 wires
Made by Turkey
There are 3 different versions of our machine
5 wire 2 cm slabs
10 wire min 5 cm slabs (for thick stone with separate hoops each)
36 wire 2 cm slabs

SCHINDMACHINES SMW10 MULTI WIRE GRANITE & MARBLE BLOCK CUTTING MACHINE
Natural stone block cutting machines have gained a quite different level with the latest technology. Wire gang saw or, in other words, multi wire block cutting machine, has become the first need of factories.
Schind has succeeded in being a solution partner for cutting granite blocks or cutting marble and travertine blocks for manufacturers who want fast production.
Thanks to its strong chassis structure and separately pneumatic wire tensioning, you can cut plates of different thicknesses with high precision.
We proud of to say we have high demands received for the Schind multi wire gang saw that we have developed in-house from the domestic and international markets.
Supporting the cutting group with a hydraulic cylinder has increased the life of the system 5 times by reducing the load on the nuts and reducer system to 10% during the up and down movement of the machine.
Linear rays are completely protected by bellows.
With our SCHIND SMW10, SCHIND SMW15, SCHIND SMW38 models, we have succeeded in being the supplier of manufacturers who make slabs from block with these cutting-edge multi-diamond wire block cutting machines. With this diamond wire stone cutting technology, we succeeded in overcoming difficulties such as precision in multi-plate cutting, ability to move independently of the vein structure of the stone, and faster product removal with less breaking from the gang saw.
The cost of diamond wires is around 30% more than that of the saw blades. These values ​​may differ depending on the type of stone and the quality of the diamond wire.
Based on the same number of blades and wires, multi-wire cuts 3 times faster than the gangsaw blades.
Minimum slab thickness is 18 mm at lamella gangsaw block cutting machine. Minimum slab thickness is 8 mm thin with the shifting technique in the multi-wire block cutting machine.
Since the lamellar gang saw works with back and forth movement, it makes a hydraulic impact to the stone block and the cracked stone slabs can be easily broken. This does not happen in multi-wire gangsaw, the stone is cut without impact.
If we explain mathematically so that our customers can make correct calculations and compare the machines;
The energy consumption of the Multiple Wire Block Cutting machine is 110 KW.
Let’s say our block is 3 meters. Cutting speed is 60 cm/hour.
3mt x 0.6 = 1.8 m² x 44 diamond wires then we can get max = 79.2 m² / hour
110 Kw / 79.2 m² = 1.38 Kw / hour / m²
The energy consumption of the 80 Blades Gang-Saw Block Cutting Machine is 160 Kw.
Let’s say our block is 3 meters. Cutting speed is 20 cm/hour.
3mt x 0.2 = 0.6 m² x 80 = 48 m² / hour
160 Kw / 48 m² = 3.33 Kw / hour / m²
Result: We spend 1.38 Kw/hour cutting 1 m² of plate with diamond wire block cutting method… We spend 3.33 Kw/hour when cutting 1 m² with a gang saw block cutting method …

Small and normal block cutting machine

CTX GRANİTE CUTTING CENTER
The CTX 1203-40 G is a granite block cutting machine, the contents of which are highly technological and innovative, permitting to achieve in real terms.
The bridge is made of electro welded steel construction in order to avoid resonance during the working phase of the discs.
The machine assembly is composed of the fallowing major components:
-One disc holder trolley
-One main bridge
-Two cross beams
-Four columns
The block is located stationary below the machine ,The machine performs all the processing movements.
The disc holder trolley and the spindle housing are built in one solid, completely machined, welded steel frame.
A large hinged door, mounted on one side of the disc holder trolley, permits easy access to the disc housing for vertical discs replacement.
Two V shaped guides situated on the main bridge guides the movement of the disc holder trolley along the main bridge.
Two interchangeable bronze alloyed cushions, made of antifriction metal, are mounted between disc holder trolley sliding surfaces and V shaped guides.
Zero-clearance in the V shaped guides and two preloaded roller system provide continuous, precise, forced contact between the discs holder trolley and the main bridge. This guarantees perfect vertical discs performances.
Four very strong and heavy columns guide the vertical movements of the cross beams/main bridge assembly.
The guides for the vertical movements, positioned on the four columns, are completely machined and protected by labyrinth-type fixed covers.
The vertical displacement are driven by four precision screws mounted on the columns and by four lead nuts mounted on the cross beams. The rotation of the screws is synchronized with three connecting shafts.
The vertical displacement screws rotation axis is controlled by a position encoder connected to the PLC to permit programming of the vertical displacements directly from the main electric panel.
The working cycles are completely automatic. The sequence of the processing operations can be programmed in accordance with every requirement for granite cutting.
The machine is controlled by Programmable Logic Control units (PLC) and all the working parameters are visualized on 10 inch color touch screen control panel. The main motor is 160kw and driven by electronic frequency inverter so the speed can be adjusted according to the material and different size of discs.
The machine has pendulum cutting system that the discs can not impact to the block directly. When they start to cut the discs perform the cutting inside the stone. The discs cooling water feed is controlled by a safety sensor, which causes the machine to stop in case of water pressure drop. The working parameters and the diagnostics are visualized on the display.
The machine painted surfaces were treated with the fallowing painting procedure: sand-blasting, surfacing, double layer of bi-component epoxy primer, double layer of polyurethane enamel.

The Tornado gang saw is the result of over 23 years of ZMK’s experience in the natural stone sector. The gang saw was designed for the quick sawing of marble blocks. The model Tornado is available in the versions with 80 and 100 blades. The blade frame is at a fixed height and moved by a double connecting rod, whilst the block carrying trolley is installed on a platform which rises towards the diamond blades.
The frame moves on a system of V type sliders that run along oil bath steel guides. Thanks to the use of special metals and mechanisms this is an extremely efficient, simple system with very low friction resistance that does not require complex dynamic or hydraulic mechanisms and requires very little maintenance.
The block lifer platform moves precisely up on 4 slides (2 flat and 2 prismatic) fixed to the columns and plated with a thick coat of chrome to guarantee a long working life. The lifting of the platform is guaranteed by four big screws of large diameter working perfectly synchronized. All slides are opportunely protected by rubber or stainless steel guards, as to avoid water infiltration and sawing residuals that could compromise the efficiency of the gang saw as time goes by.
The flywheel weight 9.500 Kg and made of a cast iron. The diameter of the flywheel is 3.500 mm which is one of the heaviest and largest flywheels in the market. It guarantees a constant cutting speed.
The system with two connecting rods provides clear and time tested advantages over a single connecting rod system. All the power and mechanical thrust transferred to the blade holder are shared between two connecting rods instead of just one.
ZMK’s gang saw is supplied with touch screen control panel. This system allows the complete supervision and programming of the cutting phases. In fact, this system enables to set various cutting speeds according to the different cutting phases (beginning, intermediate and final).
· 1 pcs transfer waggon and 2 pcs block waggon are available.
· The machine stops in case of lack water and water cuts.
· The power panel is placed over the ground to prevent it from getting affected by water.
· The plugs of block and transfer waggons are water resistant.
· The flywheel and connecting rods are surrounded by safety barriers.
· The machine is controlled by PLC and touch screen.
· The block waggon can be locked vertically and horizontally.
· The machine is able to be accessed by internet connection for determining the problems.
· 10 tons hydraulic tensioner and spacers are available.
· Slab break sensors are available.

TOKSEL MULTIWIRE BLOCK-CUTTING MACHINE: MEGALODON
Megalodon which offers various wire thickness options, is first launched with 5.3mm. wires in İstanbul Marbletech fair. Thin wires provide high cutting speed and less waste of raw materials. The precision cut feature of the machine transforms raw stones in the quarries into high value added products.
With hot-dip-galvanizing and epoxy paint MEGALODON is firm in any condition. It has TOKSEL’s traditional all-over-auto lube system as well.
Compared gangsaw machines, Megalodon allows changing thickness settings more practically when needed. You can produce from 15 to 65 cm. slabs, now with much higher performance with Megalodon.
Industrial Advantages of MEGALODON
High cutting speed
Minimum waste of raw materials
Lower foundation expenses
Less space
Cuts both marble and granite
Energy saving up to 25%
Less need for workforce
Able to cut slabs