MARBLE DRYING AND SURFACE TREATMENTS

EMA machine has been manufacturing Hot-Air dryers (electrical or natural gas), IR (infrared) dryers, Elevator Dryers, UV (ultraviolet) curing equipment and some other auxiliary machineries such as conveying systems, working tables, resin filling machineries to be used in these marble surface treatment processes.

Drying systems developed by EMA have occupied highly important place in drying from UV based chemicals through epoxy based chemicals by Ultraviolet, MARmax Elevator dryers.

The availability of Ema marble equipments and the auxiliaries provides the customers to meet the right solution with the excellent result for the following processes; drying lines before selection, filling lines for surface holes, surface cracks filling lines. UV based chemicals and relatively UV drying lines are mostly used in surface filling and repairs. UV based polyesters are commonly used in these applications. Unlike, it is highly important to use UV resin where Labor health & Safety are proceeded accordingly.

In some kinds of marbles and travertines, it causes negative impact why it contains moisture inside because of their nature structures which disable “selection process”. Therefore, these negative effects of the natural stones should be removed before selection process. The most used method in drying (take off water) is infrared drying which should be equipped with infrared lamps (infrared heating elements like IR heater are not recommended) and closed circuit hot air circulation. Irmax infrared dryer developed by EMA group is able to dry any kind of natural stones like marble, travertine and limestone to the desired temperature for the appropriate application. So, the water inside the stones is easily removed and no condensed water remains in the systems.

Even though epoxy polyester mastic fillers have been still used in conventional drying ovens in many territories, the developments of UV technology, relatively new generation chemicals, UV epoxy acrylics enable IR + UV combination drying systems to be used, especially in Europe and the other developed countries.

In the past, the higher IR & UV lamp costs and more expensive UV resins made customers consider the high costs of investments with UV chemicals. Later on, it is obviously realized that, it would help to increase productivity and efficiency in the way of higher speed curing/drying, increased production volume by means of UV + IR combi-systems. It should be known that UV & IR lamps have minimum 1.000 hours operating life time, IR infrared lamps operating life time can easily go up to 5.000 hours.

As to be known, the waiting or delays on this process, which consists of calibration, pre-cleaning, drying for moisture, filling, drying and varnishing is not desired by customers. First drying (oven) unit is used for removing moisture within the stone’s structure, as quick as possible. IR drying ovens assembled by EMA innovated-patented IR reflectors are dressed up by IR lamps in determined distance and in order. Although a surface is quite satisfactory to be dried, theoretically, the stones are dried throughout the deepness, which gives a full drying from the top to bottom of it. After UV epoxy resins are applied onto the dried stones (marbles) in filling process, UV epoxy resins are able to be cured and to be hardened depending on the number of UV lamps and power output, quickly. IR + UV combi-dryers (ovens) provide an optimum length of Drying & Curing line to get the best result with the less space using in less investment in a short term.

In general, cracks repairing process has brought some more difficulties along after marble cutting operation. In another words, if any marbles or stones is not taken away completely from moistures in the structure or water on it, then, conventional epoxy or UV epoxy resins can not be filled in cracks properly. Even if possible, it can not be glued or stuck surrounding the sides of cracks in depth. Therefore, it is recommended to be used IR drying oven systems in two sided, top-bottom section together, to remove moistures and water away from the surface and in the structure.

To be able to ease gelling with conventional epoxy or UV epoxy, it is certainly required to adjust the viscosity prior to the application by means of drying oven heat-control. Because the earlier gelling with conventional epoxy or UV epoxy than being planned can not fill in the cracks and leak out.

EMA marble system makes two different cracks repairing-filling lines:

IR infrared drying lines

UV curing & drying lines (currently not available at the moment)

In crack, repairing Epoxy applications are generally used in the process. The water inside the marble must be removed before epoxy resin applications. It is made either by Irmax infrared dryers or by MARmax elevator dryers if there is also available elevator dryer after epoxy resin application in a continue line process.

These two processes in marbles with no-cracking problem can be made in this line at the same time. For instance; IR drying oven + epoxy or UV epoxy resin application + UV epoxy curing combi-system. Unlike, the process in marbles with cracking problem is set up as following; 1st IR drying oven + cracks repairing line + 2nd IR drying oven + surface cleaning + surface cracks filling line + 3rd IR drying oven this type of large flexible cracks & holes filling / repairing marble machinery lines are available to be used in multi-purposes.

Using a special UV resin developed by GAMİ chemical provide a very high surface quality with glossy/shiny effect. This special UV chemical, MoreCure MMP developed by

GAMİ chemical also prevents waterabsorption into the limestone and any stains and dirt like ketch-up, coffee remains on the surface.