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JOURNAL
EDITION 2019 | 2020
Breton Journal 2019 | 2020
Preview IN QUESTO NUMERO IN THES ISSUE
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Luxmaster KG 5000 TANGO
Breton VEIN MATCHING
Contourbreton NC 300 ROBOCUP
Contourbreton NC 300 ROTARY
Luxmaster KG 5000 TANGO
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HYPEROCK TECHNOLOGY
GENYA with belt table
GENYA offers new possibilities
Breton by MISTRELLO
SAMPLES PRODUCTION LINE
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J. ROTHERHAM’S New investment
NC 300 ROBOCUP
HANS EISENRING
Breton DIGIHUB
Breton SPAREPARTS
Breton SMARTDOC
Breton SMARTBI
Breton SKYNET
Breton SENTINEL
ETERIAL® QZ e CK
Bretonstone KREOS®
Breton research develops BIOQUARZO®
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HYPEROCK TECHNOLOGY
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Breton by MISTRELLO
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Breton Journal 2019 | 2020
CERESER has chosen the NEW Breton KG machine for its granite polishing operations CERESER MARMI SPA has specialised in the selection and sale of marble and granite for more than half a century. One of the highest profile stone works on the international market, the company has always combined industrial production logic with a personal approach in its customer relations. CERESER MARMI is based in Rivoli Veronese, 34 km from Verona. In June 2019 the company started working with their latest investment: a new Breton LUXMASTER KG TANGO polishing line of the latest generation, equipped with oscillating spindles which produce absolutely unprecedented gloss levels of the slabs! Luxmaster granite polishing lines are the soundest investment for companies requiring high productivity, top quality and operational ease, while maintaining budget-friendly operating and maintenance costs. Breton was the first company to develop machines for the continuous polishing of granite slabs, bringing about a radical change in the industry. Today, thanks to the company’s matchless, long-term experience, factors such as automation, productivity, no-compromise quality, low operating
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costs and ease of use and maintenance have become the norm for Breton, all of which are skillfully implemented into the exemplary Luxmaster. LUXMASTER KG TANGO radically solves the polishing shade problem along the edges of the slabs, thanks to the clever spindle assembly oscillating system, whose swinging motion, interpolated with that of the beam, follows curved work paths that may be configured as desired depending on the material to be machined. The result is a consistent quality finish on the whole slab surface, both for polishing and honing. Luxmaster KG Tango is a carefully designed and well-made investment to keep your company moving ahead!
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Breton Journal 2019 | 2020
BRETON VEIN MATCHING How it works in 7 steps Programming the cutting of slabs by coupling different slabs and matching the veining is now extremely simple through the new Breton Vein Matching software. It is capable of simultaneously managing up to 8 slabs, and it offers a 3D image of the project starting from the project’s 2D drawing in DXF format. This allows making sure that the combined slabs will have a satisfactory appearance and that the “continuous vein” effect is fully achieved, before actually cutting the slabs.
Different materials and thicknesses can be used at the same time to prepare alternative solutions of the same project, which may then be compared before actually proceeding. The software allows you to continuously view the final result even during its creation, and also to carry out modifications while working; this means maximum flexibility and being able to evaluate the highest possible range of available combinations and effects.
1. Project import 2D-project files may be imported from any CAD environment in DXF format.
2. 3D processing A 3D version of the various pieces included within the project itself is generated for all imported projects.
3. 3D layout composition Generated components may be assembled in a 3D layout, identifying the involved surfaces and the relevant contact points.
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4. Slabs selection from the magazine Slabs are digitally stored in the magazine; as such, the ones to be used to create the components may be easily selected.
5. Component positioning on the slabs The components to be processed may be initially attributed per individual slab, therefore reducing possible machining waste.
6. Final definition of the components Thanks to real-time processing, you can assess and adjust the finished result of the project in accordance with the desired bookmatch veining effect, by modifying positioning and orientation of the pieces directly.
7. Final view export to be proposed to the client At the end of the development phase, the final view’s layout may be exported and shown to the client for final evaluation. The steps can be repeated over and over to offer a range of aesthetic variations to the customer. Once the client has made his/her choice, all you have to do is launch the approved project in the machine to start actual production
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Breton Journal 2019 | 2020
BRETON VEIN MATCHING What our customers say Vein Matched Perfection Vein Matching is poised to be the fastest growing trend in 2020. Having the right tools to deliver on customer expectations is the difference between fabrication shops surviving and thriving. Advanced 3D Capabilities Breton’s Proprietary Vein Matching software enables users to transform their 2D DXF files into 3D renders. “The 3D formatting helps when presenting to the client. A little bit of flash goes a long way to instill confidence in the client that we are working with state-of-the-art tools and equipment.” - Owner, Lesher Natural Stone, Frank Lesher Using the software, fabricators are able to map out multiple layouts and compare options, to select the perfect flow for each client and project, before ever making their first cut. “The complete kitchen put together in 3D is very impressive and also extremely useful that they are basically looking at their finished kitchen before the slabs have even been cut.” - Owner, Lesher Natural Stone,
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Frank Lesher Users can simulate the light and shadows in the room through the software, replicating how veins will appear to a customer as sunlight moves throughout the day in the rendered room. “Slab positioning has been most useful in our highly veined slabs. It not only makes it much easier for us, but also negates all the risk with the client because they can see it ahead of time and sign off with their approval.” - Owner, Lesher Natural Stone, Frank Lesher This unique feature saves fabricators time, money, labor, headaches, and most importantly, ensures a great experience for their clientele. Incomparable Accuracy In addition to the high-tech image fabricators project with the Vein Matching software’s computer generated visual aides, Breton provides a leg up through its accuracy in positioning slabs for the perfect match. Prior to using Breton’s Vein Match software, “slab layouts were tedious to do and were done by laying out on the slabs themselves with tape” - Owner, Lesher Natural Stone, Frank Lesher Now, Lesher Natural Stone, manages up to 8 slabs at once, of different materials and thicknesses through the Vein Matching software, streamlining otherwise time-consuming multi-slab jobs.
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within only a couple of days. “Speed of layout, speed of cutting, confidence in our job and what we will deliver to the client, ease of mind that everything is figured out ahead of time and the client agrees.” - Owner, Lesher Natural Stone, Frank Lesher Unlike 3rd party applications, Breton’s software is developed to work seamlessly with their machinery, and other programs, like Breton Touch. Breton’s Vein Match automatically programs cutting cycles, and generates the tool path, applying unique parameters of the material used. “I would recommend that others get the software because it makes the work faster, easier, and more accurate.” - Owner, Lesher Natural Stone, Frank Lesher. About Lesher Natural Stone
“Jobs that used to take 1 hour are now done in 15 minutes.” - Lesher Natural Stone, Alexia Lesher “We have about 15%-20% less waste now due to how much of the slab is being utilized, this also saves money.” - Lesher Natural Stone, Alexia Lesher With improved accuracy, fabricators virtually eliminate material waste, drastically reduce time and labor costs, and deliver more premium work with significantly better margins. Intuitive Software
Lesher Natural Stone, is a family owned business, now run by the fatherdaughter team, Frank and Alexia Lesher. For over 25 years, Lesher Natural Stone specializes in unusual and custom work. Like many fabricators, Lesher’s company struggled with placing seams and matching veining, before turning to the Breton solution one year ago. Lesher chose Breton for their world renowned reputation, quality of product, and customer service. They now use Breton Vein Match on half of all jobs, finding it easier to do more complicated custom work, and expand their margins. Is your shop ready for what customers will be demanding in 2020? In the last year, Lesher Natural Stone reduced the time spent on each vein match job by 75%, while attracting and impressing more customers. How will you compete?
Vein Match is an extremely intuitive software that is easy to learn. Lesher’s team showed fluency in the program within a week, and were running it
7 Reasons Vein Match is the Most Advanced Vein Matching Software on the Market: 1. Manages up to 8 slabs of different materials and thickness. 2. Generates the tool-path and applies the parameters of the material you’re cutting. 3. Unlike third party applications, Breton’s Vein Match integrates seamlessly with Breton machinery. 4. Automatically programs cutting cycles around your digitally perfected vein match. 5. Transforms 2D DXF files into 3D renders 6. Compares different layouts for the perfect flow before cutting to present to clients. 7. Incomparable accuracy leads to less material waste and more premium work with significantly better margins.
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Breton Journal 2019 | 2020
BRETON VEIN MATCHING What our customers say About Lesher Natural Stone Like many fabricators, Lesher’s company struggled with placing seams and matching veining, before turning to the Breton solution one year ago. They now use Breton Vein Match on half of all jobs, finding it easier to do more complicated custom work, and expand their margins. 1. Who is Lesher Natural Stone? “We are a small family-owned business that specializes in unusual and custom work. Unique projects are what set us apart from the crowd. We have been in operation for over 25 years now and we do a mix of commercial, residential and we also get into restoration projects.” 2. How did your collaboration with Breton Start? “We considered getting a Breton saw 25 years ago and when we started looking again, we wanted a quality piece of equipment that had all the sophistication of today’s technology from a company with years of experience. There was no trip through Italy this time, but we
took a motorcycle trip down to Florida to conduct research at the stone convention, Coverings.” 3. Why did you choose Breton? “We decided to go with Breton because of the company’s reputation, quality of product and customer service. We saw how much the Bridge Saw can do, the old bridge saw was a Simec and we had it for 25 years and it worked great but it cuts and you have to stand there while it cuts versus this which is so high tech, part of it is the vein matching and it comes with the camera that we can take photos of the slab and use it with the vein matching. We didn’t set out to find vein matching software, it was thrown in a with a package, but we were really surprised with how much that helped. The vein matching was something unexpected, and how much we use it now was extremely unexpected to us. The products and the customer service are our favorite parts of working with Breton.” 4. What is the best feature about the Vein Matching Software? “The 3D formatting helps when presenting to the client. A little bit of flash goes a long way to instill confidence in the client that we are working with state-of-the-art tools and equipment. The complete kitchen put together in 3D is very impressive and extremely useful that they are basically looking at their finished kitchen before slabs have been cut.” 5. How has the Vein Matching Software changed your process? “I did not think the product would be of much assistance, but I was very happily proved wrong. The product is a huge help especially in working with products with lots of veining. We used to do layouts on the slabs themselves with tape, this was the most time-consuming portion of the job, it used to take up to 1 week to complete one project. The biggest challenge was laying seams and matching the veins. Slab positioning has been the most useful in our highly veined slabs. It not only makes it much easier for us but also negates all the risk with the client because they can see it ahead of time and sign off with their approval.” 6. How has Breton changed the type of work you perform? “We are doing more complicated custom work now with the software and machine. Jobs that used to take 1 hour are done now in 15 minutes. I like using the product for those multi-slab jobs since it cuts down on time. We just did a restoration job that was milling custom molding, we had to bring in 3-inch-thick slabs of travertine from Italy and mill those to match existing molding the Breton Bridge Saw was really awesome for that.” 7. How has the square footage capacity of your shop changed? “Our through-put square footage has increased greatly because we are getting through jobs more quickly. We have been able to have more competitive pricing since we are spending less time on each job and saving money.”
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8. Have you noticed any changes in slab waste since using Vein Matching? “We have about 15%-20% less waste now due to how much of the slab is being utilized, this also saves money.” 9. How has Vein Matching impacted your labor costs? “We don’t have as many man-hours on the machine which allows us to get more jobs through the shop since the jobs take less time and that Breton saw really runs itself, you put the slab on, and you walk away. We run the saw all day and occasionally, we will have a night shift just so that we can get stuff through. And if we are getting jobs done faster it just means we can get through more jobs, so our job volume has increased.” 10. Do you recommend the Breton Vein Matching Software? “This software helps with a lot of the speed of layout, speed of cutting, confidence in our job and what we will deliver to the client. Ease of mind that everything is figured out ahead of time and the client agreed. There was lots of interest from our staff and within a couple of days they could do the basics and within a week or two they were fluent with the software. I would recommend that others get the software because it makes the work faster, easier, and more accurate.” 11. What are your plans going forward for the company? “We always want to increase job volume going through. This year we are looking to expand our facility a little bit, grow our building and make more room for more slabs and have more room for growth down the line. Our shop is getting full of our equipment, so we want to make room down the line for when we are going to need it. We are looking to start doing glazed ceramics inhouse so we want to get a big kiln, there is a very traditional craft in Italy which is covering lava stone in glaze and then firing it, it’s usually used in outside tables, we want to bring it over here since it doesn’t really exist in the United States.” About the Software Breton’s Proprietary Vein Matching software enables users to transform their 2D DXF files into 3D renders. fabricators are able to map out multiple layouts and compare options, to select the perfect flow for each client and project, before ever making their first cut. Users can simulate the light and shadows in the room through the software, replicating how veins will appear to a customer as sunlight moves throughout the day in the rendered room. This unique feature saves fabricators time, money, labor, headaches, and most importantly, ensures a great experience for their clientele. Incomparable Accuracy In addition to the Vein Matching software’s computer generated visual aides, Breton provides a leg up through its accuracy in positioning slabs for the perfect match.
Users manage up to 8 slabs at once, of different materials and thicknesses through the Vein Matching software, streamlining otherwise timeconsuming multi-slab jobs. With improved accuracy, fabricators virtually eliminate material waste, drastically reduce time and labor costs, and deliver more premium work with significantly better margins. Intuitive Software Vein Match is an extremely intuitive software that is easy to learn. Operators show fluency in the program within a week, and are running it within only a couple of days. Unlike 3rd party applications, Breton’s software is developed to work seamlessly with their machinery, and other programs, like Breton Touch. Breton’s Vein Match automatically programs cutting cycles, and generates the tool path, applying unique parameters of the material used. To learn more about how Vein Match can impact your business, write to us at info@breton.it
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Breton Journal 2019 | 2020
Contourbreton NC 300 ROBOCUP Higer efficiency, less manual interventions When your company acquires a Contourbreton you can rely on an extensive range of customisations to allow the best possible use of the machine in compliance with your needs and, above all, to achieve HIGHER MANUFACTURING EFFICIENCY. When you choose Contourbreton with the “FAST LOCK” system, composed of the ROBOCUP work bench and special vacuum cups, you will be able to clamp all your workpieces on the cups without having to join vacuum hoses up with the connector. The operator’s work becomes much easier, precise and neat. The system is based on a work bench containing vacuum manifolds that create a vacuum in the cups, thanks to easily replaceable valves mounted on the bench surface. Thanks to the Robocup vacuum cup (Breton patent), vacuum is generated both in the cup and on the workpiece without any requirement for hoses, on/off valves, or batteries for vacuum generation, which would demand recharging and maintenance. The vacuum cups are automatically positioned on the work bench by the machine spindle thanks to a magnetic pick-up system; once the work process is completed, they are stowed for future requirements at the rear of the machine in a dedicated magazine (if provided). Alternatively, the operator can safely enter the working area and clamp the cup to the pick-up device mounted on the spindle. Once the processed workpieces have been unloaded and the bench has been washed, the dedicated “FREEPASS” software controls the automatic repositioning of the vacuum cups in preparation for the following work processes. Benefits? • Exceptional production efficiency thanks to optimisation of space on the work table, with multiple workpieces processed on the same table. • Reduction of work bench setup times between one work process and the next. • Increased productivity per shift for each operating unit. …last but not least: semi-finished product loading and processed workpiece unloading are performed automatically, with no need for an operator to reposition the vacuum cups before each new process.
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Breton Journal 2019 | 2020
Contourbreton NC 300 ROTARY Higher productivity with less effort thanks to the front worktable changeover function ContourBreton NC300 Dual, the enormously successful double table machining centre that has already been shipped to a large number of customers, has been further refined from the technical standpoint, resulting in the advent of the ROTARY version. This rugged CNC router is perfect for the requirements of big enterprises that need to produce large series, but also for smaller firms keen to build their business and raise the evolutionary level of their production process. Specifically designed to work natural stone, engineered stone and sintered materials, this machine can handle all the necessary machining processes without compromise in terms of performance. When installed in a Fab-Shop, this machine can be interfaced with the Xpress Top kitchen worktops and bathroom counters production software. The new external layout immediately sets this machine apart from its predecessor. This evolution makes it possible to control the machining centre completely from just one side, thanks to the new front worktable changeover mode. Production performance can be further increased thanks to the reduced table changeover time available by selecting the automatic doors open/ close option. This allows the operator to focus on the all-important task of setting up the worktable. A key feature of ROTARY is the modular design of its parts, allowing
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customers to mix and match the various internal accessory packages available. The ROTARY series is available with two spindle variants: with HSK-B80 or ISO 40 tool holder clamping systems. The configurations available feature 3 or 4 axes with accessories capable of supporting a very wide range of machining processes. ROTARY is also exceptionally easy to use, thanks to the ergonomic console and userfriendly operator interface. The simple and intuitive approach adopted for the operator’s use of the machining centre even makes it possible to perform CAD-CAM programming operations directly on board the machine.
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Breton Journal 2019 | 2020
TECHNOLOGY The future of resin treatment for difficult materials The evolution of natural stone markets has led manufacturers to seek out ever more unusual and hard to treat materials to maximise consumer interest in the search for the uniqueness and exclusivity that are the quintessential properties of the product in its natural state. Materials such as exotic or super-exotic granites, semi-precious stone or quartzites are in ever growing demand for the creation of surfaces in high-prestige spaces.
for processing difficult materials, so that’s precisely what we did.
However, these materials need to be treated carefully, adopting methods and technologies that are very different from the customary approaches, since they are very frequently non-homogeneous in nature, composed of a large number of chemical elements, often of very different types. The lack of viable alternatives meant that producers were obliged to return to the original methods, overcoming the absence of industrial technology by the intensive use of skilled manual labour to recondition, consolidate and upgrade the appearance of blocks and slabs. Clearly, process costs and times in particular have been radically affected by this type of approach.
The ability to produce consolidated slabs (not merely glued or patched, as with the classic resin treatment process), in a single pass rather than the two, three or more needed in the past, in conjunction with intraplate resin penetration in schistose or micaceous materials, mean that production costs can be reduced by 50/60%.
When Hyperock® was first conceived in the Breton Research Centre, based on an idea of Ing. Toncelli, our thoughts were focused on this new market. Hyperock® technology was made possible and industrially viable by a group of researchers who spent more than a year on the project. Only by means of a pressure-impregnation process was it possible to perform the necessary quantum leap in terms of reduced times and costs
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Today, with the first series production plant fully operational at the Antolini stone processing plant (Verona), we can finally confirm that the results we achieved actually outstripped our expectations, especially in relation to the economic/production advantages provided by the new system.
Like other discoveries in world history, this generational change has triggered a series of chain reactions that are accelerating the evolution of work processes, so Breton is now ready to offer a different version of Hyperock®: consolidation without the use of reinforcing meshes or mats, particularly suitable for translucent materials. In addition, Breton can build plants of various sizes and production configurations to meet all requirements. The compact resin lines that treat slabs in a single pass allow companies to optimise their production times and costs with only a relatively modest level of investment.
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Breton Journal 2019 | 2020
GENYA with belt table The GENYA bridge saw is equipped with a cutting spindle on a rotating head that is also equipped with workpiece vacuum cups in order to optimise the surface area to be cut. The enormous success of the Breton GENYA, a monobloc NC bridge saw with fixed work-table that’s exceptionally compact and rapid to install, persuaded Breton to extend the range: the Breton GENYA, equipped with a belt table to be used in slab cutting lines, hits the market. Breton GENYA with belt table is the most productive and flexible solution, ideal for fabshops specialised in both medium-large series production for the building trade and for single slab optimisation procedures for the furniture sector (kitchens, bathrooms, etc.). No basement The machine is simply secured to the floor. A software for any situation The machine’s software interface is easy to use and may be operated on different sophistication levels. The “Fast and Easy” level allows the operator to rapidly and easily carry out all simple cutting operations using the colour touchscreen.
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Through the “Professional” level, the operator can program more complex cutting and shaping operations. The control console is equipped with a joystick to easily move the several machining axes. Everything you need. • Automatic tilting saw blade between 0° and 90° • Inverter motor/spindle • 1/2” gas connection for core drill attachment • Through-spindle water • Slab thickness probe for miter cuts with continuous automatic correction of the cutting measurements and saw blade diameter electronic control. • Pick-up unit with vacuum cups and optimization software with automatic nesting • Vein matching software (page 6) on demand.
Let’s shape the future together
We have changed our logo, but not what we do. We are a company of the Swiss Habasit Group and for over 60 years we have been producing gear reducers and gearmotors worldwide known for their high quality. We design reliable and customized solutions enhancing productivity and minimizing TCO (Total Cost of Ownership).
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Breton Journal 2019 | 2020
GENYA OFFERS NEW POSSIBILITIES Learn about the accessories and software With Genya new accessories, Fabshop machines become even more modern and performing. The GENYA monobloc bridge saw, which was exhibited at MARMO+MAC 2018, has now extended its range of smart accessories with: 1 - Automatic labelling system installed onboard the spindle. The LabelPro system allows pieces to be labelled directly on the machine before being cut, thereby eliminating the need for manual operations or standalone marking stations. This system ensures labels are perfectly positioned on the cut piece, with no room for approximation. The entire process is managed by the Genya software system. Each labelled piece will be easily and univocally identified through the QR code printed on the label.
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The labeller is housed in a hermetic and pressurised case to guarantee absolute reliability. - Available label sizes: 110x60 mm; 100x50 mm; 90x40 mm - Indicative average application time of each label: 4 sec. 2- Supplementary electro-spindle with vertical shaft, 3.7 kW/14,000 rpm, specifically designed for the use of finger bit tools and mounted laterally to the spindle holder carriage. It comes complete with a dedicated software. 3 - Breton Vein Matching – software suite to combine 3D surfaces arranged in a “diamond-match” pattern. Incredibly easy Go to page 6 for more information This allows making sure that the combined slabs will have a satisfactory appearance and that the “continuous vein” effect is fully achieved, before actually cutting the slabs.
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PASSION AND COOPERATION
VUOTOTECNICA LEADER IN TECHNOLOGIES FOR VACUUM MANAGEMENT AND USE BY THE SIDE OF BRETON, FOR OVER 30 YEARS
VUOTOTECNICA PRESENTS
THE NEW “VACUUM SOLUTIONS CATALOGUE”: AN OVERVIEW OF THE FULL PRODUCT RANGE
The ultimate expression of the company’s ethos, featuring the very best of Vuototecnica know-how, at the service of project designers, builders and operators of machinery and systems, enabling them to perform industrial processes on marble, granite and ornamental stone in general.
Breton Journal 2019 | 2020
Breton by MISTRELLO the new integrated storage-plant solution for the stone industry Increasingly smart slab storages, extremely high automation levels, superior safety at work and space optimization. This is what the modern stone industry needs. This is why Breton decided to renew its Value Proposition in slab handling and storage and remnant management. Breton offers the best solution by entering the market with its partner company Mistrello, the leader in slab-shaped products storage. With over 1400 installations in the glass segment, it can now offer highly flexible solutions to the stone world as well, which can be perfectly adapted to the extreme customizations currently required by this market. The winning synergy comes from the combination between Mistrello’s immense slab handling know-how and Breton’s undisputed knowledge of both the stone world and the organization of complex industrial processes. Breton by Mistrello is now the new and perfectly integrated smart solution to store and process slabs. Customer benefits: - Space optimization: the stored material takes about 1/3 of the space required by fixed stand traditional systems; • Space costs reduction (land and building rent/purchase); • Higher storage capacity with the same space. - • •
Work safety: all elements are supported by and run on floor-fixed rails; as such, the structure is solid and safe. The storage are equipped with new generation anti-tilt systems that protect the operators’ health and safety. Minimizes the chance of accidents at work. Improves your employees’ working conditions.
41 sqm with 730 slabs thick 12 mm - 440 slabs thick 20 mm
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Process automation: the need for operators is reduced to a minimum, as the process is completely automatic and the operator’s role is only that of supervising and controlling it. Reduces staff costs for low added-value activities. Increases the productivity of your plants.
1 - Single Compact Storage Solution - 250 slabs 18 positions Capacity: 250 slabs (20 mm) Minimum footprint: 24 m2 (10 slabs/m2). 2 - Double Compact Storage Solution - 1000 slabs 31+31 positions Capacity: 500+500 slabs (20 mm) Minimum footprint: 100 m2 (10 slabs/m2). 3 - Double Stack handling solution - 1360 slabs 104 positions; Capacity: 1360 slabs (20 mm) Minimum footprint: 160 m2 (8.5 slabs/m2). 4 - Ultramatic 5000 handling solution - 5080 slabs 452 positions; Capacity: 5080 slabs (20 mm) Minimum footprint: 620 m2 (8 slabs/m2).
Marmo Arredo, Pier de Plan, KEMIE, Tuytelaers and J. Rotherham, two companies that have been worldwide benchmarks for years in terms of innovation and automation in producing kitchen tops, have already chosen Breton by Mistrello.
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160 sqm with 2250 slabs thick 12 mm - 1360 slabs thick 20 mm
310 sqm with 5030 slabs thick 12 mm - 3020 slabs thick 20 mm
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Breton Journal 2019 | 2020
SAMPLES PRODUCTION LINE Promote your brand with an automatic samples line by Breton A highly competitive market such as the stone and ceramic sector obliges manufacturers to produce large quantities of top quality samples very quickly. Tecnema Breton Group, a Maranello-based company specialised in the design and construction of machines and equipment for the ceramics industry, has worked with Breton to develop a series of automatic solutions for the production of samples. This has led to the development of various proposals to meet the needs of companies seeking different levels of automation and investment. These lines are extremely versatile, capable of working with all stone and ceramic materials – from conventional ceramics and natural stone to engineered stone composites. For example, the Compact line is semi-automatic and offers medium production capacity: with a limited investment it allows users to optimise
their production times and costs. The top end of the system is composed of fully automatic production lines, customised to meet the specific requirements of each customer and characterised by their high production capacity and low demands on the workforce. All the lines can be integrated in a plant supervision system in compliance with Industry 4.0 principles. The typical process starts with strips of polished material which are first split in the thickness dimension. The base is then gauged in order to obtain samples of uniform thickness. Thereafter the samples are cut to the required size and shape and, when required, polished and edge-chamfered. Finally, the samples are washed, dried and unloaded from the line. The sizes of samples vary from around 40 mm to 300 mm, with thicknesses from 5 mm to 20 mm. Production capacity depends on the finish, dimensions, and thickness, with maximum output levels of up to 4,0005,000 pieces per shift.
Levelling
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ng di Worki
Overturning
Splitting
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Two-sided polishing and chamfering Cutting to size
Sorting of samples
Washing and blowing
Two-sided polishing and chamfering
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Breton Journal 2019 | 2020
J. ROTHERHAM’S NEW INVESTMENT Fully automated plant processing 50 slabs/shift Founded in 1927, , one of the biggest UK manufacturers of bespoke kitchen worktops, stone fireplaces and architectural components in complex shapes and all sizes, continues to stand at the forefront of technological innovation applied to the production of natural and engineered stone components.
new production plant and the two Smartcut SNC 550 OPTIMA lines previously installed in the same J. Rotherham production facility.
To guarantee the highest possible levels of customer satisfaction and meet increasingly stringent time-to-market demands, J. Rotherham decided to invest in the latest and most innovative technology by acquiring a Breton plant for fully automated production of quartz worktops.
possible space, the creation of a flexible system to supply multiple cutting lines, fully automatic offcuts management: these are just some of the essential aspects that concur in defining the enormous potential of this type of storage system.
The heart of the plant lies in the Breton Xpress Top smart software suite, which controls the entire worktops production cycle. The package chosen by the UK company includes three modules: Design, Inventory and Production.
On departing from the storage system, the slabs are first cut to size to obtain the various components of the kitchen worktop. The pieces are then forwarded to the downstream workstations in accordance with the established workflow logic.
This solution, which has been fully integrated with J. Rotherham’s ERP system, has reduced the firm’s operating costs and brought big gains in terms of competitiveness. THE PLANT The plant provides for identification of each slab in the new Breton By Mistrello vertical storage system to allow selective picking for order lists. The Breton By Mistrello slab storage system is capable of supplying the
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The slab storage and handling system was completely designed to J. Rotherham’s specifications. Large quantities of slabs in the smallest
The type of bespoke kitchens manufactured for the UK market called for an exceptionally flexible cutting system that could also offer the precision guaranteed by Breton. That is why the UK company opted for two Breton Combicut combined diamond blade and waterjet cutting systems with 5 interpolated axes. The cut pieces, offcuts, and the largest pieces of scrap are unloaded from the cutting station automatically and forwarded to the downstream processing stages.
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The slab edges are prepared on the Breton OD Flex By Optidrive edge polisher, where the entire polishing phase is managed without operator intervention thanks to the use of an industrial robot.
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Breton Journal 2019 | 2020
J. ROTHERHAM’S NEW INVESTMENT Pieces requiring a sink and/or hob cutout, plus other types of edge processing or drainage grooves are machined on a robot island composed of 6 Breton NC300 K26 Robocup contouring machines with a robot tending system. The automation system was designed to optimise workpiece management times, reduce the number of operators needed for the loading/unloading process, and to move the material through the process efficiently with the shortest possible cycle times. Another result of this system is the creation of a safe workplace for operators, while simultaneously minimising the risk of damage to materials associated with manual handling operations. The Industry 4.0 plant, equipped with robots and smart software for production planning and productivity management, gives the company a major competitive edge on the market. The production cycle is tracked and monitored right up to the stage of quality control and shipment to the end customer. The intense collaboration between Breton and J. Rotherham during the plant project, development, installation and startup phases made it possible to fulfill the customer’s requirements in the shortest possible time.
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Expertise – Passion – Automation
Innovation and efficiency for industrial automation Since 1959 SMC has been a synonym for innovation in the pneumatic component industry for industrial automation. SMC offers 12,000 basic products and more than 700,000 variants such as air treatment, fluid control equipment, valves and actuators, and it also offers state-of-the-art solutions for the automotive industry, the electronic industry, the food industry, the machinery and life science industry.
Valves
Electric Actuators
Sensors
Thermochiller
Air Treatment
Vacuum Components
SMC Italia S.p.A. Headquarter: Via Garibaldi, 62 - 20061 Carugate (MI) - Tel. 02 9271.1 - Fax 02 9271365 Production unit: Località Recocce - 67061 Carsoli (AQ) - Tel. 0863 904.1 - Fax 0863 904316
www.smcitalia.it mailbox@smcitalia.it
Years of experience in Research & Development of customized industrial coatings
Inver Spa · Bologna · Italy Ph. 39 051 6380411 · www.inver.com Inver is member of The Sherwin-Williams Company
Breton Journal 2019 | 2020
The Hans Eisenring AG company has been renowned all over Switzerland for over 30 years for its production of high-quality kitchens and for the professional consultancy and assistance services offered to its clients. In 2016, the steady increase in market demand volumes drove the Eisenring family to consider the creation of a new production hub to boost the kitchen worktops division. The new factory would have ensured high production performances capable of meeting the planned increase in sales, while reducing labour production costs without compromising the proven quality level of the company’s products. The only way to achieve such results was to implement a high level of automation coupled with accurate, safe and reliable process machines, which should therefore integrate the Industry 4.0 concepts. With the support of several technical consultants, the Hans Eisenring AG team got in touch with several leading automation and machinery companies for stone processing. After carefully and accurately analyzing the numerous technical solutions offered, on January the 10th 2018, Breton was chosen as the main supplier of the new facility’s machinery. Breton was given the client’s full confidence because it was believed to be up to the difficult technical challenge at hand.
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The construction works for the new multi-storey building that would accommodate the new production hub and the relevant offices in Matzingen started in April 2018, while Breton was designing and assembling the required machinery and developing the innovative software required to manage and control the production process. Using advanced automation with prototyped solutions allowed the company to: • Optimize space use in the multi-storey and multi-area building • Reduce operator presence in the production departments to a minimum • Boost safety in the plant areas • Ensure consistent productivity throughout different working shifts • Sustain high process reliability • Maintain consistent product high quality standards
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The adopted high-automation solutions achieved highly flexible productive processes; in fact, the system was designed to process the several types of raw materials in demand on the market (from natural stones to highly technical products such as ceramics and engineered stones) and to carry out different finishing processes based on the clients’ needs. For the most part, the supplied machines were “foundation free� and customized in order to adapt them to the process logics and the needs discussed and agreed with the Hans Eisenring AG technicians, creating as such a truly unique plant.
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Breton Journal 2019 | 2020
BRETON All the applications developed by Breton for Industry 4.0 are gathered in a single, functional suite called Breton DigiHUB.
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BRETON ordering spare parts has never been so easy and quick The Breton Spare Parts platform is an E-commerce portal to search and order original spare parts for our machines. The service is freely available to all Breton clients and may be accessed through the SPARE PARTS button on the left upper corner of the menu bar on the breton.it website. The platform may be accessed from any device, even off-line! It could be defined as the Amazon of Breton spare parts, and like other e-commerce sites, it allows: - finding what’s needed via intuitive and quick browsing; the machine drawings may be browsed in order to identify the spare part code; - checking in real time whether the required parts are available; - uploading a customized spare parts list; - submitting an inquiry and a spare parts order; - credit card payment.
Why should you submit order via Spare Parts? 1. Because you can rapidly find the required spare parts by code or description. 2. Because you can access the spare parts catalogue. 3. Because the platform may also be consulted off-line, by downloading the spare parts catalogue to your device to use it even when you’re not connected. 4. Because a multi-user mode is available to define roles and authorizations for multiple company operators, who will then be able to simultaneously search and order spare parts.
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Breton Journal 2019 | 2020
BRETON the documentation software that simplifies information access The innovative multi-platform software designed to view machine manuals and load digital content such as documents, videos and notes changes its name and improves its functions. The previous DOC Mobile is now Smart DOC, whose new implementations make the interactions between the software and the operator more intuitive; documents are now easier to browse and faster to refer to.
You will be able to: • Use the search function through voice control; • Automatically generate the QR code for any document, then print it and associate it with the correct location in the machine. • Easily and effectively interact through the new Terabee smart sensor’s gesture recognition function.
Smart DOC consists of four elements that may be assembled modularly based on the specific needs of each company:
DOCView, the web-application that allows using SmartDOC’s functions from the company PCs via browser..
MyDOC, the function that allows adding and storing your enterprise documentation to a dedicated cloud.. DOCMobile the app that makes the technical documentation available right by the machine through your device, tablet or smartphone..
DOCRugged, Panasonic’s rugged tablet specifically designed to read the digital manuals in rugged environments, such as workshops..
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All the technical documentation will be supplied in digital format and consultable on the user-friendly SmartDOC interface. Benefits include: - multi-device consultation; - customisation with notes, photos and videos; - manuals updated automatically.
Why should you choose Smart DOC?
With SmartDOC, your manuals can be consulted on multiple devices: - area consoles - any iOS or Android device (tablet, smartphone, laptop) - desktop PCs - DOCrugged tablet.
ALL THE BENEFITS OF PAPER, WITHOUT PAPER MANUALS AVAILABLE ONLINE AND OFFLINE ON MULTIPLE DEVICES
DIRECT ACCESS TO INFORMATION VIA QR CODES ON THE MACHINES
Point your device at the QR Code affixed to the machine and the software will open the specific manual automatically.
NUC (SmartDOC+Sentinel)
A SECURE SPACE FOR STORAGE AND SHARING
MANAGE THE MANUALS FOR MULTIPLE MACHINES, THE ENTIRE PLANT OR THE ENTIRE COMPANY
With SmartDOC, your documentation i s available to personnel and safe from unauthorised alteration or distribution thanks to the use of encryption and data protection systems.
SmartDOC is a single solution for all the documentation of the machines in y our factory. A complete, portable reference source for use during machine maintenance activities.
DOCmobile DOCrugged
NUC (SmartDOC+Sentinel)
DOCmobile DOCrugged
DOCview myDOC
DOCview
DOCview myDOC
Elaborazione dati power BI Server SmartDOC + Sentinel
er ry S
Cloud
to Fac
Documentazione tecnica online
ver
r rveel e S oft tin ros r Sen c i M fo
verOC r e S D tonSmart e r B for
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Breton Journal 2019 | 2020
BRETON Business Intelligence applied to Bretonstone systems Smart BI is the multi-platform software solution designed for all Breton systems that can analyse in detail all production processes. Smart BI can gather information from different sources, e.g. MES (Manufacturing Execution System) and WMS (Warehouse Management System ) systems, machine controllers or customers’ databases and ERP (Enterprise Resource Planning) systems. All gathered data are automatically sorted and ready to be submitted and analysed through intuitive analytic or real-time interfaces.
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Smart BI can gather all relevant data on systems, lines and machines and offer the information in actionable format on specific interfaces for technicians, senior operators and managers. It can simplify and reduce the time required for customized analysis by putting information in context and thus speed up process understanding in a pragmatic and focused manner, to streamline it in the best possible way.
Why should you choose Smart BI? 1. Because it enables continuous process and product improvement by reducing lead times and production costs and increasing quality, through quick system data access and continuous performance monitoring. 2. It offers real-time production information that is rapidly actionable when required. It is designed for the whole chain, from HQ to managers, quality controllers, senior operators and operational resources. 3. It enables knowledge gathering by transforming data into information, building easy and reliable data and report models using process information.
Smart BI consists of three elements: 1. SMART BI Data Model The process that stores and models data to change it into accessible and ready-to-use information. 2. Real Time Monitoring The multi-platform environment that can represent the information in real time and allows building dash-boards that can supervise processes by monitoring them to detect possible variations. 3. Overall Manufacturing Analytics The analytic environment that can granularly analyse the available data, extracting precious information that enable supervised processes optimization and understanding.
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Breton Journal 2019 | 2020
BRETON the production line supervisor Breton Skynet is a hardware and software technology specifically designed for processing lines consisting of multiple machines and equipment. It was created to streamline the workload for managers and operators. The system is Industry 4.0-compliant. Its main features are:
•
Viewing the main data of the currently running production process by means of an in-line synoptic graph. Relevant information such as line and individual machine status are available at a glance.
•
•
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Tracing and viewing the machining runs carried out on each individual product unit processed by the line.
Gathering and viewing the main statistical data of the production process, also tracing the process data changes carried out by the individual operator.
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•
Automatically adjusting machining parameters based on: - Data receipt related to a job order; - Process information gathered during slab machining.
•
The benefits of Breton Skynet technology in 5 points: 1. Real-time process view from a single position. 2. Global and complete overview on the production process status. 3. Human error reduction thanks to the automatic management of machining processes. 4. Availability of all information required for decision-making by line managers and operators in a single screen. 5. User-friendly and intuitive software.
Viewing the production schedule defined by the Manufacturing Execution System (MES) or by the operator;
The console with display placed near the line allows a global view on the process in its vicinity. Its technology allows viewing actionable data and information on any type of enabled device (desktop PC, tablet, smartphone and web app) connected to the company network. It’s easy and intuitive to use: operators are trained by means of a dedicated Web-based video tutorial. Skynet’s interface can exchange information with production management enterprise IT systems (MES, ERP, SAP, …). Data exchange between systems is customized by an expert team based on the specific needs of the company.
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Advanced solutions for manual and automatic STONE finishing
The common applications in stone industry are extrusion and spraying two-components products. Wagner offers innovative tools, equipment and system for the application of resin and products for treatement of natural stone.
Mechanical mixing
Electronic mixing
Electronic gear mixing
www.wagner-group.com
Breton Journal 2019 | 2020
BRETON for productivity Breton Sentinel for Productivity • Real-time automatic collection and processing of production data • Creation of charts and reports • OEE (Overall Equipment Effectiveness) automatic calculation • Recording of production cycle times, inactivity times and maintenance times • Real-time monitoring of the machine through dynamic displays • Customizable operator interface • Data backup on the main server (optional) • Always-on data access with devices (PC, tablet, smartphone, etc.) • Warning signals and push emails in case of malfunctions or values below/above a given threshold • Human-machine interconnection with Twitter-like social platforms
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Real-time production data monitoring and analysis • Production data display, such as working hours, produced workpieces, tool operational time and power consumption; moreover, everything can be detailed by shift, job order or material • OEE (Overall Equipment Effectiveness) calculation • Visual alarms on machine health • Real-time man/machine interconnection via social platforms such as Twitter Spindle monitoring and tool operational time • Spindle operation real-time display • Actual work data comparison with the theoretical usage curve • Spindle overload visual alarms • Spindle expected life extrapolation
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Ordinary maintenance • Management of the ordinary maintenance fully integrated to the actual functioning of the machine • Scheduling of maintenance operations with display of the interventions and materials required • Planning of maintenance operations according to a regular time basis and/or the occurring of specific conditions (e.g. when exceeding a given threshold) • Inclusion of customized contents relevant to the maintenance operations (photos, videos, control reports)
• • •
Backup, management, and display of the machine documentation (operating handbooks) provided by the manufacturer Chronological tracking of the maintenance operations performed an consequent trend analysis and comparison Recording of the user and time needed to carry out the maintenance.
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Breton Journal 2019 | 2020
ETERIAL® QZ and CK The ideal partner for low thickness quartz and ceramic slabs Bretonstone® Quartz is attracting ever more acclaim in the world of furniture and architecture and its range of potential applications is constantly evolving. To meet emerging requirements on the market and extend the application possibilities of Bretonstone® Quartz, Breton has developed and patented Eterial® QZ, a new and entirely unique product in its field.
has been coupled with a Bretonstone® Quartz slab of approximately 6 mm in thickness.
Eterial® QZ solves the need for panels that combine very low weight with high thickness and strength, since the material features an upgraded Bretonstone Quartz surface of just a few millimetres in thickness.
Eterial® QZ is an eco sustainable material, composed primarily of recyclate and materials from renewable sources.
Eterial® QZ is an ultralight panel, from 2 to 4 cm thick, with a mineral base and specific gravity of around half that of wood, extremely strong, stable, impermeable, heat insulating, and easy to process, even using dry machining methods. The material is designed to have a thermal expansion coefficient that is the same as that of Bretonstone® Quartz, so the panel remains perfectly flat - even in changing ambient temperatures - once it
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The Eterial® QZ / Bretonstone® Quartz composite panel has huge potential for use in the furniture and interior design sector and in architectural projects in general.
The Breton Research Centre has developed a similar material in parallel Eterial® CK, designed for bonding to ceramic slabs. This is a hard, lightweight and inorganic product with specific properties of stability, durability and resistance to fire. Eterial® CK is the ideal product for bio-buildings and outer claddings.
Romani Components
Ball screws
Linear guides
Precision racks and pinions
Precision planetary reducers
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Danfoss Drives Unleash the intellingence from within Optimize performance with
intelligent drives
www.danfoss.it
Breton Journal 2019 | 2020
Bretonstone KREOSÂŽ The new super-thin quartz-resin slabs offering a unique appearance! Breton has completely revolutionized mixture distribution technologies to create slabs of different thickness with peculiar and unprecedented aesthetic effects. The new KreosÂŽ process, patented by Breton, can also produce extra-thin slabs down to a thickness of 5 mm, and opens the quartz market to new applications in interior design, furnishing and renovation.
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This new technology also has an important benefit from the sustainability perspective because it reduces processing scraps by 40% and thus minimises the energy required to gauge slabs, therefore allowing a significant reduction in production costs.
SECTORS KORTA has always stood out for its high degree of flexibility, which is why they are leaders in different sectors, including energy, logistics and civil engineering. Moreover, in its constant evolution process, it seeks high added value markets.
Machine tools
Automotive
cut Civil enginering
SCIENCE
Helping customers worldwide
Logistic
weld
FLY
TAILORED SOLUTIONS PHARMA
rivet
clamp eject TUFT
broach polish Mill
grind
MEASURE
press roll
TEST
KORTA has extensive experience in offering solutions that adapt to its customers’ needs. It has its own design and manufacturing department that can develop ball screws that adapt to the distinctive characteristics of different sectors.
punch
Inject
turn
KORTA has developed products for such demanding sectors such as aerospace or injection moulding and presses.
Inyection moulding and presses
Melt
bend
Energy
Aerospace
www.korta.com
I NASTRI TRASPORTATORI DIVENTANO UNICI THE CONVEYOR BELTS BECOME UNIQUE La tecnologia RFID all’interno permette: The RFID technology inside allows:
*
TRACCIABILITÀ TRACEBILITY IDENTIFICAZIONE IDENTIFICATION
INNOVAZIONE 4.0 Dal 1956, Scala spa opera nel campo della distribuzione industriale, offrendo una gamma di prodotti e servizi sempre più diversificata, ulteriormente ampliatasi grazie alla acquisizione della Megaveneto srl. LA NOSTRA MISSIONE: offrire ai clienti prodotti, servizi, ed idee in grado di renderli sempre più competitivi. Since 1956 Scala operates in the field of industrial distibution, offering an increasingly diversified range of products and services, wich has further expanded thanks to the acquisition of the company Megaveneto srl. OUR MISSION : to offer to our customers, products, services and ideas, capable of making them more and more competitive
CARATTERISTICHE TECNICHE: Una speciale tecnologia RFID permette la tracciabilità, l’identificazione e la tipologia del nastro (misure, data di acquisto, materiale, fornitore utilizzato, ecc.). È possibile inoltre inserire informazioni personalizzate su richiesta del cliente.
INFORMAZIONI PERSONALIZZATE
su richiesta del cliente
PERSONALISED INFORMATION
TECHNICAL FEATURES: a special RFID technology allows the traceability and identification of the belt (measurements, purchase date, material, supplier, etc.). It is also possible to insert additional personalized infomation upon customer request.
at request
CON TECNOLOGIA RFID
RFID TECHNOLOGY
SCALA SPA Sede: Torri di Quartesolo (VI) - Via Pola, 33 Tel. 0444.265555 - Fax 0444.267294 info@scala-spa.com - www.scala-spa.com
Breton Journal 2019 | 2020
BRETON RESEARCH DEVELOPS BIOQUARZO® The new frontier for environmental sustainability Breton has developed the technology for manufacturing Bioquarzo® slabs, a synthetic mineral obtained through an exclusive process of pyrolytic transformation of common siliceous sands from natural deposits or residues of industrial processes, mixed with other minerals. With properties that are equivalent to those of natural quartz, Bioquarzo® can be used as a raw material to replace natural quartz or cristobalite granules and powders for the fabrication of Bretonstone Quartz slabs (commonly referred to as “quartz slabs”).
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Bioquarzo® is manufactured also in a super-white version to meet the multiple aesthetic demands of Bretonstone Quartz. Bretonstone® Bioquarzo® slabs do not contain crystalline silica, so they can be processed in full compliance with environmental health standards.
LA LUCIDATRICE PER MARMO CHE ABBINA TRADIZIONE E INNOVAZIONE THE MARBLE POLISHING MACHINE THAT COMBINES EXPERIENCE AND INNOVATION
printed in italy by Laboratorio Grafico BST - 09/19 - EN
Breton S.p.A. Via Garibaldi, 27 - 31030 Castello di Godego (Treviso) Italy tel. +39 0423 7691 - fax +39 0423 769600 - e-mail: info@breton.it - www.breton.it
TECNEMA Breton Group Via Abetone Inferiore, 44 - 41053 Maranello (Modena) Italy tel. +39 0536 942433 - fax +39 0536 942449 - e-mail: sales_dep@tecnema.it - www.tecnema.it