Drying line with oven

INKA presents most suitable solutions for you by using latest technology in designing and manifacturing of lines with oven with is 16 years experience in industry. The most appropriate drying capacities and drying costs are archieved by optimising 4 main procedure of drying (heat, volume, and velocity of air, time, exhaust ratio) in INKA drying ovens.
Our lines that are designed as ovens with electrical resistance, IR, gas or UV according to needs and conditions have following common characteristics;
- 65 cm (strips) and 200 cm (slabs) operation width
- Water scraping ventilators for predrying
- Air and heat insulation at entrance and exit of oven
- Insulation of all oven walls (bottom, upper surface and two sides) with 10 cm stone wool
- Heat insulation seals on all metal metal connection points
- Epoxy based paint that is resistant for moisture
- Ungraded speed control and conveyors that increase drying productivity
- Independent, illuminated and ventilated operation tables
- Exhaust outlet with adjustment valve
- One graded or multi graded thermostatic control
- High drying productivity
- Parts that are manufactured according to internationaþ standards, reliable, high quality and can be found easily
- Low maintenance cost.

CRACK REPAIRING + HOLE FILLING LINES

Many stones have both cracks and holes at the same time. These stone ruquire both crack repairing and hole filling. If there is not a problem of being broken during calibration and pre polishing process, two problem can be solved in one application by applying only epoxy after pre polishing (for micro cracks and micro holes) or only mastic (for channel type cracks and macro holes). But if there is a problem of a being broken, two different operations a necessary; crack repairing should be done just after cutting process and then stones are subjected to hole filling process. Many factories tend to use same line in both crack and hole repairing, as their place and financial shortages. All these conditions have brought out the need of "DUAL SYSTEM FILLING LINES" that give opportinity to make both crack and hole repairing at the same machine. Total investment cost of filling-repairing line decreases %30-%40 with these lines. DUAL SYSTEM running synchronously with polishing machines daytime shift as hole filling machines; is used as crack repairing line independently during night shift when the stones are not polished.

Dual System for Strips

Dual System for Slabs

CRACK REPAIRING LINES

The most widely used repairing material is epoxy-based resin as it strenght, thermal expansion, viscosity, price/quality parity specifications are suitable in crack repairing. The most important subject in epoxy application is to dry all micro cracks inside the stone completely. Otherwise, a little moisture remained in the cracks prevents epoxy from penetrating into cracks; even if it flows into cracks, moisture prevents it from penetrating on crack wall.
Drying the stone on bottom and upper surfaces at the same time for dehumidifying cracks in depth, increases drying capacity %140; in other words, required drying time decreases %60.
Generally, crack repairing is done immediately after the cutting process. Stones that have cracks are separated; brought to entrance of line and then dryed on two sides. Suitable epoxy mixture is applied until it fills into cracks completely. If epoxy with %25 catalyst is used, stones are kept in natural factory conditions 1 day summer and 2 days in winter by covering each stone with nylon. Stones are given to polishing machine after complete polymerisation (becoming hard) of epoxy. After application, stones can be kept in elevator ovens or batch oven to shorten polymerisation time and together (store) stones in the same place. If high temperature is applied, it becomes gel very quickly. But this is underisable situation as it prevents epoxy from penetrating properly. Drying in oven after epoxy application is a process that should be done very carefully. For this reason, polymerisation in natural environment without oven is preferred in many situations. The most important matter in crack repairing lines is that drying process should be done very well before epoxy application . Heaters running with gas and electrical resistance are more widely used in crack repairing line ovens. In some situations IR heaters can be used to shorten lenght of line.
Desire to fastest polymerisation after application and required time for efficient penetration is a paradox. For example, UV resin that can polymerise very quickly with UV lambs is rather viscose and needs long time for penetration. Similarly, epoxy resins that can polymerise very quickly are moreviscose than others. That is to say, these resins that can polymerise quickly have higher viscosity, but it prevents resin from penetrating in depth. Generally, while polymerisation time is becoming shorter, its prices increase at the same time. Finally, the most suitable material to use in crack repairing is epoxy with %25 catalyst in this century's technology.

Crack Repairing Line for Strips

Crack Repairing Line for Slabs

HOLE FILLING LINES

Mastic and resins that can polymerise quickly are preferred in hole filling. Because, This is a continious process that can be done as "Calibration and/or prepolishing + Drying + Filling + Polymerisation + Polishing" and waiting is not desirable after filling.
There is two ovens in these lines: Drying oven and polymerisation (making hard) oven. Both of two ovens are heated only upper side, because hole filling is a superficial process that is applied on only upper surface with the aim of removing visual defects.
Heaters with electrical resistance and IR are widely used in hole filling lines as only upper surface of stone is heated. These lines can be manufactured as running with gas according to needs. If Uv resins that are sensitive to UV rays are used as filling material, polymerisation (making hard) oven is equipped with UV lambs that have suitable power, wave lenght, size and shape. The shortest filling line can be obtained with a composition of IR oven UV polymerisation oven. But, backup costs of IR and UV lambs are quite high . Resins that are sensitive to UV rays are still quite expensive. Finally , the most widely used material in hole filling polyester based colourful mastics that can be polymerised in ovens.

Hole Filling Line for Strips

Hole Filling Line for Slabs

TRAVERTINE DRYING LINES BEFORE SELECTION

Travertine absorbs high amounts of moisture naturally and it is difficult to dry it. Even if classical drying ventilators at the end of production lines dehumidify surface, it makes impossible to do accurate selection as moisture in depth of stone comes to surface of the stone.
Two sided (bottom and upper side) heating system is used in these lines as crack repairing lines. There are cooling ventilators at the end of line for the situation of holding stones by hand. There is not ventilating unit on operation (selection) table as epoxy is not applied on the table. There is only independent illumination.
Heaters running with gas and electrical resistance are used more in Travertine Drying Ovens. IR heaters can be used to shorten the lenght of line, if it is required in some situations.

INKA presents most suitable solutions for you by using latest technology in designing and manifacturing of lines with oven with is 16 years experience in industry. The most appropriate drying capacities and drying costs are archieved by optimising 4 main procedure of drying (heat, volume, and velocity of air, time, exhaust ratio) in INKA drying ovens. Our lines that are designed as ovens with electrical resistance, IR, gas or UV according to needs and conditions have following common characteristics; 65 cm (strips) and 200 cm (slabs) operation width Water scraping ventilators for predrying Air and heat insulation at entrance and exit of oven Insulation of all oven walls (bottom, upper surface and two sides) with 10 cm stone wool Heat insulation seals on all metal metal connection points Epoxy based paint that is resistant for moisture Ungraded speed control and conveyors that increase drying productivity Independent, illuminated and ventilated operation tables Exhaust outlet with adjustment valve One graded or multi graded thermostatic control High drying productivity Parts that are manufactured according to internationaþ standards, reliable, high quality and can be found easily Low maintenance cost.
CRACK REPAIRING + HOLE FILLING LINES
		Many stones have both cracks and holes at the same time. These stone ruquire both crack repairing and hole filling. If there is not a problem of being broken during calibration and pre polishing process, two problem can be solved in one application by applying only epoxy after pre polishing (for micro cracks and micro holes) or only mastic (for channel type cracks and macro holes). But if there is a problem of a being broken, two different operations a necessary; crack repairing should be done just after cutting process and then stones are subjected to hole filling process. Many factories tend to use same line in both crack and hole repairing, as their place and financial shortages. All these conditions have brought out the need of "DUAL SYSTEM FILLING LINES" that give opportinity to make both crack and hole repairing at the same machine. Total investment cost of filling-repairing line decreases %30-%40 with these lines. DUAL SYSTEM running synchronously with polishing machines daytime shift as hole filling machines; is used as crack repairing line independently during night shift when the stones are not polished.
Dual System for Strips

Dual System for Slabs



CRACK REPAIRING LINES
		The most widely used repairing material is epoxy-based resin as it strenght, thermal expansion, viscosity, price/quality parity specifications are suitable in crack repairing. The most important subject in epoxy application is to dry all micro cracks inside the stone completely. Otherwise, a little moisture remained in the cracks prevents epoxy from penetrating into cracks; even if it flows into cracks, moisture prevents it from penetrating on crack wall. Drying the stone on bottom and upper surfaces at the same time for dehumidifying cracks in depth, increases drying capacity %140; in other words, required drying time decreases %60. Generally, crack repairing is done immediately after the cutting process. Stones that have cracks are separated; brought to entrance of line and then dryed on two sides. Suitable epoxy mixture is applied until it fills into cracks completely. If epoxy with %25 catalyst is used, stones are kept in natural factory conditions 1 day summer and 2 days in winter by covering each stone with nylon. Stones are given to polishing machine after complete polymerisation (becoming hard) of epoxy. After application, stones can be kept in elevator ovens or batch oven to shorten polymerisation time and together (store) stones in the same place. If high temperature is applied, it becomes gel very quickly. But this is underisable situation as it prevents epoxy from penetrating properly. Drying in oven after epoxy application is a process that should be done very carefully. For this reason, polymerisation in natural environment without oven is preferred in many situations. The most important matter in crack repairing lines is that drying process should be done very well before epoxy application . Heaters running with gas and electrical resistance are more widely used in crack repairing line ovens. In some situations IR heaters can be used to shorten lenght of line. Desire to fastest polymerisation after application and required time for efficient penetration is a paradox. For example, UV resin that can polymerise very quickly with UV lambs is rather viscose and needs long time for penetration. Similarly, epoxy resins that can polymerise very quickly are moreviscose than others. That is to say, these resins that can polymerise quickly have higher viscosity, but it prevents resin from penetrating in depth. Generally, while polymerisation time is becoming shorter, its prices increase at the same time. Finally, the most suitable material to use in crack repairing is epoxy with %25 catalyst in this century's technology.


Crack Repairing Line for Strips

Crack Repairing Line for Slabs



HOLE FILLING LINES
		Mastic and resins that can polymerise quickly are preferred in hole filling. Because, This is a continious process that can be done as "Calibration and/or prepolishing + Drying + Filling + Polymerisation + Polishing" and waiting is not desirable after filling. There is two ovens in these lines: Drying oven and polymerisation (making hard) oven. Both of two ovens are heated only upper side, because hole filling is a superficial process that is applied on only upper surface with the aim of removing visual defects. Heaters with electrical resistance and IR are widely used in hole filling lines as only upper surface of stone is heated. These lines can be manufactured as running with gas according to needs. If Uv resins that are sensitive to UV rays are used as filling material, polymerisation (making hard) oven is equipped with UV lambs that have suitable power, wave lenght, size and shape. The shortest filling line can be obtained with a composition of IR oven UV polymerisation oven. But, backup costs of IR and UV lambs are quite high . Resins that are sensitive to UV rays are still quite expensive. Finally , the most widely used material in hole filling polyester based colourful mastics that can be polymerised in ovens.
Hole Filling Line for Strips

Hole Filling Line for Slabs


TRAVERTINE DRYING LINES BEFORE SELECTION
		Travertine absorbs high amounts of moisture naturally and it is difficult to dry it. Even if classical drying ventilators at the end of production lines dehumidify surface, it makes impossible to do accurate selection as moisture in depth of stone comes to surface of the stone. Two sided (bottom and upper side) heating system is used in these lines as crack repairing lines. There are cooling ventilators at the end of line for the situation of holding stones by hand. There is not ventilating unit on operation (selection) table as epoxy is not applied on the table. There is only independent illumination. Heaters running with gas and electrical resistance are used more in Travertine Drying Ovens. IR heaters can be used to shorten the lenght of line, if it is required in some situations.