Toksel Machine a recommendation for entrepreneurs and those considering new investment: Mosaic

Machinery and Equipment Required for Marble Mosaic Production

Mosaic Production

Entrepreneurs and enterprises considering new investments may not be able to select equipment they will start use in the production of marble mosaic. It makes me happy that this article is going to be a remedy and disperse the uncertainty clouds I observe.

What is Mosaic?

In the Dictionary published by Turkish Language Association, mosaic is defined as painting and decoration work made by bringing together small cubic pieces of marble, stone or terracotta pieces.

It is a word of French origin and is written in French as mosaïque.

We don’t need to get in the details in our first article about mosaic production. I’m sure you would like to make your pre-feasibility preparations with summary information. The necessity of a detailed feasibility is as real as what you read. But if this is the first technical article you read about mosaic production, you’ll need some more preliminary research. Let’s start…

Important questions to be answered before starting mosaic production

Our two most important questions are: “Which products and which markets do we target?” and “What is our raw material measurement range?” Which markets do we target with which products? After asking this question, you should note your answers carefully. They will be useful for our next articles.

I have classified mosaic production in three basic categories in terms of efficiency. I am also aware that you wonder why there are three categories and why such a classification is needed. As I said at the beginning of the article, we will not be a pain in your brain with those details. In the production of marble mosaics, the machinery and equipment required by the average manufacturer will be more than enough.

I classify our marble mosaic production as follows;

• High series production with high investment in technology and high value-added product,

• Medium series production with normal (medium) technology investment and high value-added product,

• Low series production with low technology investment and high value-added product,

These three classifications are valid for this article (we will give details in our latest article on mosaic production) and you will read further different classifications in the following days.

Marble Mosaic Production Requirement List

1. A production area suitable for stocking raw materials with a closed area of 1000 m2 where wastewater treatment / sedimentation is planned: 20 × 50 mt (Offices, infirmary, dining hall, washbasin, etc.)

2. Forklift and pallet truck

3. Setting stands

4. Selection tables

5. Gluing stands

6. Drying racks

7. Production and packaging of marble mosaics (mentioned as titles)

8. Raw material

• Raw Material in Mosaic Production

The type and size of the raw material is the most effective factors determining the stages of our marble mosaic production.

In this article, we will call all the natural stones which are below 30 centimeters in the past, which were called as tile fractures and which were not used by the tile manufacturers, in other words, which are not offered to the market as “ideal mosaic raw material. Ideal mosaic raw materials which we call as tile fractures under thirty centimeters can be marketed as final products after being sized of 5, 7.5, 10 and 15 cm. This situation has prevented mosaic producers from supplying tile fractures under thirty cm and forced them to work with larger raw materials.

Recognizing this added value, our plate and tile manufacturers as well as all over the world, have recently embarked on the production of marble mosaic, anticipating that they can use natural stone resources more efficiently. The best example of this in our country is Fimar and Fimart models. Many companies, which started to produce marble mosaic in order to evaluate the wastes, have witnessed that they can create more added value with less energy per unit time.

Many plate and tile manufacturers have started to utilize the raw material obtained from the quarry, with their mosaic production workshops established within their bodies. This situation has prevented the loss and damage during transportation and stacking, and has added value to our country. This has led to the marble mosaic producers to reach raw materials for higher prices.

While the processes vary according to the physical properties of the raw material, the necessary machinery and equipment changes according to the processes. At this point, the width x length x thickness data of the ideal mosaic raw material are important.

Based on the general market, I took my raw material thickness as 3 centimeters and width as 30 centimeters. According to these ideal mosaic raw material properties, I have listed the processing machines that are required to be in my machine section.

• Machinery and Equipment Required for Marble Mosaic Production

I wrote our machines one by one according to the order of processing of the ideal mosaic raw material, so that the machine sequence also shows you the process sequence.

Our first marble processing equipment Alligator ® 33 Mini Splitting Machine: 2 heads and 4 heads are available. The maximum width it can handle is 34 cm and can split a raw material of 3-5 cm thickness into two pieces. It has now become two raw materials of 1-1.3 cm thickness.

Pegasus ® Calibrating Machine 48 cm: It is used to smooth the rough surfaces of two raw materials, which have splitting saw marks. It gives them mosaic width standard of 0.8-1 cm. The bridge is fixed machine. For mosaic, the ones with 2, 3 and 4 heads are widely used. Antique mosaic, semi-finished products, polished mosaic and honed mosaic can be produced if the raw material is suitable.

Multi-Blade Sizing Machine Alligator ®: Marble is the most important pillar of the production process. It usually has bandwidth of 50 cm and one piece of material up to 43 cm width can be produced. Minimum sizing width is 1 cm. Machine quality has a direct impact on cutting quality and production speed. The ones with hive pipe/charging system and the maximum density of stainless material are the most suitable for mosaic work.

Vibrating Surface Treatment Machine: It gives a soft form to the sharp edges and corners of sized mosaic particles and provides the surface with an antique appearance. It is also known as ageing boiler in the market. It is the indispensable for fund production.

Net Drying Furnace: Mosaic tiles lined with molds and applied with glue net are put in the furnace. Tiles are sent for packaging after the nets are dried through the sides of the machine. These types of machines must have heat regulation, thermostat, steam ejector and cooler units.

Marble Mosaic Packing Machine: It is used for automatic packing of mosaic tiles with stretch before boxing. There are many manufacturers in Turkey.

Some of the marble mosaic types produced by the machines in our list are: