JADE T I L E
F E A S I B I L I T Y STUDY
NOVEMBER, 1 9 8 6
PREPARED B Y :
M. WALDNER
E . PLANK
Jj&fis and Vttnlem Kwowcei
/ <y
Victoria, E &
TABLE OF CONTENTS
INTRODUCTION
1.1
History
1.2
Terms o f R e f e r e n c e
SUMMARY
NEPHRITE J A D E CHARACTERISTICS
CUTTING, GRINDING AND P O L I S H I N G
4.1
4.2
Cutting
PROCESSES
Processes
4.1.1
H i g h P r e s s u r e Water
4.1.2
Laser
4.1.3
Abrasive
4.1.4
D i a m o n d Saws
Slurries
G r i n d i n g And P o l i s h i n g
Processes
T I L E MANUFACTURING PLANTS
5.1
Breton
s.p.a.
5.2
Gregori
s.p.a.
5.3
Pedrini
s.p.a.
5.4
C a r l Meyer
5.5
Loffler
5.6
Hensel
5.7
Mohawk
- Maschinenbau
OHG
5.7.1
Current Plant
Configuration
5.7.2
Mohawk P l a n t I m p r o v e m e n t s
6
6.
PREFERRED MANUFACTURING SYSTEM
6.1
7.
8.
D e t a i l e d Cost A n a l y s i s
- C a r l Meyer
PLANT SITE SELECTION
7.1
Terrace
7.2
Surrey
7.3
C o n c l u s i o n s and Recommendations
BIBLIOGRAPHY
TABLES AND
FIGURES
FIGURE 1
LOCATION MAP AND WEATHER COMPARISONS
FIGURE 2
BRETON SYSTEM
FIGURE 3
GREGORI SYSTEM
FIGURE 4
PEDRINI
FIGURE 5
CARL MEYER SYSTEM
FIGURE 6
LOFFLER
FIGURE 7
HENSEL
FIGURE 8
MOHAWK SYSTEM
TABLE I
PLANT COMPARISONS
TABLE I I
MOHAWK PLANT COSTS
TABLE I I I
S I T E COSTS V S . JADE RECOVERY
TABLE I V
B U I L D I N G CONSTRUCTION COST ESTIMATE
SYSTEM
SYSTEM
SYSTEM
APPENDICES
APPENDIX I
EQUIPMENT MANUFACTURERS
APPENDIX I I
JADE T I L E FEASIBILITY
APPENDIX I I I
B.C. HYDRO - POWER COST ESTIMATES
APPENDIX IV
MOHAWK JADE T I L E PLANT EQUIPMENT
APPENDIX V
STONE WORKING INDUSTRY
STUDY PLAN
COMPANIES
- 1 -
1.
INTRODUCTION
This
report,
prepared
jointly
b y M.W.
i n d e p e n d e n t c o n s u l t a n t E.M. P l a n k d e t a i l s
determine
for
t h e p r o d u c t i o n and c a p i t a l
manufacturing
tiles
and s l a b s
products
a r e t o b e made f r o m
hitherto
had been
and
production.
report
Mines
were
funded
costs
associated
with
o f which
Columbia
attractive
These
nephrite
which
volume o f r e s e r v e s
O i l Co L t d . , t h e D e p a r t m e n t
under
system
i s a t t a c h e d a s Appendix I I , a n d
o f Canada and t h e M i n i s t r y
British
an optimum
Columbia N e p h r i t e J a d e .
lower grade, y e t s t i l l
b y Mohawk
O i l Co. L t d . and
the f i n d i n g s o f a study conducted t o
from B r i t i s h
The s t u d y , a p l a n
jointly
of
o f Mohawk
unsaleable but represents a significant
and Resources
Resources
Waldner
o f Energy, Mines
the Canada/British
of
Energy
and Petroleum
Columbia
Mineral
Development Agreement.
The
s t u d y encompassed
international
technologies
available
research
Mohawks' own e x c l u s i v e
into
eventually
impetus
to
primarily
research into various cutting
l e d t o the stone c u t t i n g
for researching
the t i l e
enhance t h e economics
the
cost
of
manufacturing
The
are specific
British
this
Columbia
jade
production
Nephrite Jade.
precluded
system.
and
Europe,
manufacturing techniques.
industry
i n W e s t Germany
including
The r e s e a r c h
and I t a l y .
The
m a n u f a c t u r i n g t e c h n o l o g i e s came f r o m t h e n e e d
jade
material.
findings
America
o f mining and marketing
construction quality
study
i n North
and g r i n d i n g
the d i r e c t
tiles
and
nephrite
slabs
manufactured
to production of t i l e s
The p h y s i c a l
application
jade and t o reduce
from
and s l a b s
the
from
a
and c h e m i c a l c h a r a c t e r i s t i c s o f
of
a
"standard"
stone
tile
- 2 -
1.1
HISTORY
The
C r y Lake Jade Mines L t d . p r o p e r t i e s ,
located
i n the Provencher
Columbia
product
been
(see Figure
from
from
this
has
to
been
area
alluvial
lenses of jade.
1) .
boulders,
from
shore
market
i s mainly
carving
most
California
simplified
lower
jade
grade
a n d 4x4 i n c h
tiles
jade.
period approximately
total
investigations
manufacturing
British
as a
primary
production
mining
B.C.
has
in-situ
830 t o n s o f j a d e
t o t h e camp t h e n c e
by a i r
M o s t B.C. J a d e p r o d u c t i o n
primarily
quality
production.
into
jade.
Taiwan.
jade
The
tiles
this
plant
were p r o d u c e d
allowed
grading process
A marketing
a
developing
Jade
f o r marketing
techniques
process
the jade
some
are
This
which
off-
accounts
remaining
75% o f
below
exploration,
a market
f o r the non-
costs.
mechanism
manufacturing
Northern
n e p h r i t e jade
been u n s a l e a b l e o r f e t c h e s p r i c e s
initiated
attractive
O i l Co. L t d .
p r o d u c t i o n has been
t o o f f - s h o r e markets,
and n o n - j e w e l l e r y q u a l i t y
researching
tile
10 y e a r
2 5 % o f Mohawk's
has g e n e r a l l y
1982 Mohawk
the primary
of
Although
f o r c a r v i n g and j e w e l l e r y
development and m i n i n g
In
area
has been m i n i n g
by t r u c k t o S o u t h e r n
i t s way, i n raw f o r m ,
production
Creek
the minesite v i a "cat-train"
finds
approximately
Kutcho
t h e mid 1970's.
the past
Dease Lake and f i n a l l y
for
-
Mohawk
since
During
shipped
Lakes
now owned b y Mohawk
tiles
"lower
was
the l i b e r a t i o n
grade"
beginning
of higher
as the
jade.
After
in
southern
i n 1983.
quality
t o enhancing
c a m p a i g n was o r g a n i z e d
a n d "JADE INTARSIA" was e s t a b l i s h e d
identified
established
and s o l d
i n addition
were
jade and
the value of the
for introduction
as the t i l e
The
o f the
s e c t o r o f Mohawk's
jade business.
Manufacturing
thick
jade
tiles
the p a s t y e a r .
tile
and
business
distribution
has c o n t i n u e d
After
of
the four
inch
s i n c e 1983, a l b e i t
square
on a
an e x p e n d i t u r e o f a p p r o x i m a t e l y
and w i t h
three years
became e v i d e n t t h a t t h e p r i c e
marketing
o f the t i l e s
by
one-eighth
reduced
scale
$1.5 m i l l i o n
and m a n u f a c t u r i n g
h a d t o be r e d u c e d
inch
during
i n the jade
experience i t
i f the necessary
-
s a l e s v o l u m e s w e r e t o be
sell
or
f o r more t h a n $150
less
per
production
that
the
lower
sets,
the
costs
foot
can
including
grade
be
has
and
slab
"value-added" part
e v e n t h o u g h an
be
been
also
the
Designer Net.
set
and
this
reduced.
slabs,
must
b u s i n e s s and
economic a n a l y s i s
aspects from m i n e s i t e to s a l e a b l e
of
the
be
bulk
achievable
research
blocks.
and
p r o d u c t s can
table
i f the
if
be
for
legs,
desk
However,
remainder
t o be
tile
uses
items.
are
$100
indicates
Other
gift
jade sales
also
business would n e c e s s a r i l y
products.
currently
target p r i c e of
including
profitable
the
A
tiles
v a r i e t y of
and
identified
The
only
Market
i f a greater
tiles,
been
is
home, c o m m e r c i a l , s o u v e n i r
manufacturing
of
a viable operation.
enhanced
size
-
foot,
drastically
have
other
for
square
different
jade
b o o k - e n d s and
tile
per
s a l e s volumes can
offered,
the
square
achieved
3
of
the
economic,
include a l l
YUKON
Afh
WEATHER CONDITIONS COMPARISON
Annual P r e c i p i t a t i o n F.F.D.*
Terrace
109 cm (43")
151
Prince Rupert
286 cm (113")
n/a
Vancouver
n o cm (43")
198
62 cm (25")
68
P r i n c e George
C Mean Temp.
Spr. Sum. F a l l
6.3
15.5
Wint.
6.7
-3.1
n/a
9.6
16.9
10.7
4.0
n/a
* F r o s t Free Days
Source: M i n i s t r y o f A g r i c u l t u r e
Climate o f B.C.
FIGURE 1
NIN1U>
- 4
1.2
The
TERMS OF
study
focus
production
of
equipment
and
analysis
of
production
REFERENCE
was
to
research
nephrite
optimum
Mohawk's
jade
plant
current
inefficiencies.
technologies
were
essentially
focused
southern
(lower
although
tariff
-
to
available
tiles
and
determine
design
and
location.
tile
manufacturing
ascertained
a
northern
mainland)
and
The
plant
considerations
had
central
B.C.
included
an
identification
of
A
foreign
plant
techniques
Plant
plant
site
dictated
a
for
manufacturing
study
and
evaluated.
previously
technologies
alternate
or
location.
and
preferred
Additionally, available
be
on
techniques
Site
Selection
location
was
not
United
and
versus
a
considered
States
plant
location.
Previous
production
determining
experience
the
basic
4x4
inch
criteria
and
for
marketing
the
tile
information
assisted
specifications.
These
in
criteria
were:
1.
A
$11.00.
(approx
This
approximately
$100
2.
per
3.
$45.00
square
The
up
jade
per
to
jade
tile
a
square
was
to
total
foot
and
retail
for
less
than
manufacturer's
cost
a
of
retail
price
of
under
foot.
rates of
at
e x p e c t e d b a s e d u p o n a 40
raw
to
cm^)
translates
Minimum p r o d u c t i o n
t o be
100
blocks
dimensions
could
of
be
2x3x3
l e a s t 1100
square
f e e t per
month were
h o u r work week.
considered
metres,
but
approved
and
t o be
i n rough boulder
commonly
less
than
1
form
cubic
metre.
4.
A l l e q u i p m e n t m u s t be
CSA
compatible with
a l l Canadian
standards.
5.
The
plant
inch,
6x6
was
t o have the
inch,
minimum t h i c k n e s s
8x8
capacity
inch,
4x8
to produce s l a b s
inch
o f a p p r o x i m a t e l y 1/8
and
12x12
inch.
and
inch
bevelled
tiles
with
4x4
a
-
These
criteria
types
and
plant
expandability
capital
served
as
techniques
equipment
manufacture's
training
the
bases
available.
assessed,
costs
after
-
for
comparison
Production
yield
from
service
actual
user
of
rates
raw
identified.
sales
programs,
5
and
jade
done
feedback
costs
of
equipment
were
compared,
determined,
individual
including
and
various
boulders
Assessment
was
the
general
parts
and
equipment
availability,
industry
stature
and
performance.
Plant
Site
Columbia
"value
jade
Selection
mineral
added"
based
upon
Jade)
would
(Nephrite
approach
industry
processing
was
to
practice
off-shore.
the
of
The
m a t e r i a l and
2.
Availability
o f an
3.
Availability
and
would
of
support
Proximity
and
to
Europe.
serious
the
appropriate
cost
of
in
i n the
the
departure
material
level,
heavy
in
well
native
British
Province.
from
the
the
raw
This
previous
form
for
P l a n t S i t e S e l e c t i o n were:
costs.
force.
electric
power
and
to
a
lesser
land).
drained
production
light
equipment
industrial
without
land
the
which
need
for
preparation.
domestic
This
work
water,
(Serviced
expensive foundation
5.
is a
this
f i n i s h e d product transportation
n a t u r a l gas.
Availability
that
processed
primary c r i t e r i a
Raw
4.
premise
be
exporting
1.
extent
jade
the
and
f o r e i g n markets
includes
estimated
p r i m a r i l y the
differences
U.S.,
Asia
i n marketing
costs
between l o c a t i o n s .
6.
Impact of
weather c o n d i t i o n s
associated
costs
of
on
operating
the
a
operation,
high
water
e s p e c i a l l y impact
use
plant
in
and
freezing
conditions.
7.
Availability
and
level
Government a s s i s t a n c e
of
programs.
Federal,
Provincial
and
Municipal
- 6 -
2.
SUMMARY
This
report
manufacturing
This
study
describes
the
results
4x4
inch
thick
was
by
1/8
jointly
funded
P r o v i n c i a l Governments.
of
the
per
venture
square
was
The
study
polishing
lasers,
and/or
and
square
of
into
and
jade.
The
techniques
as
of
f o o t or
appropriate
set
research
stone
the
than
Jade.
Federal
the
and
feasibility
$100.00
manufacturing
Canadian
costs
relevant cutting,
to
or
impregnated
identifying
tools
appraisal
and
be
could
of
for
cutting
Mohawk's
identified
economically
as
and
water,
assessing others.
equipment were
which
grinding
the use o f h i g h p r e s s u r e
included
working
equipment
L t d . , and
Nephrite
of
less.
diamond
as
feasibility
Columbia
for less
total
a l l possible
well
the
for establishing
techniques including
slurries,
European manufacturers
suppliers
O i l Co.
require
t e c h n o l o g i e s and
technology
Mohawk
That
would
into
from B r i t i s h
primary c r i t e r i a
included research
grinding
tiles
t i l e s must r e t a i l
foot.
abrasive
research
t h a t the
a p p r o x i m a t e l y $45.00 p e r
The
by
of
own
Six
possible
produce
jade
tiles.
A
p r e f e r r e d manufacturer
identified
to
be
and
a plant site
establishing
the S u r r e y area)
manufacturer
lowest cost;
of
a
tile
equipment
and
recommended.
manufacturing
a
The
tile
manufacturing
a p p r o x i m a t e l y $39.00 p e r
manufacturing
best
alternative
technique
by C a r l M e y e r .
test
square
work
(probably
T h i s W e s t German
successfully
f o o t f o r 4x4
was
i s considered
p l a n t i n t h e Lower M a i n l a n d
u s i n g equipment manufactured
completed
tile
and
at
inch jade t i l e s .
the
- 7 -
3.
NEPHRITE JADE CHARACTERISTICS
There
jade
in
are essentially
(Nephrite)
this
of
a
two t y p e s
and a pyroxene
o f jade
jade
r e p o r t i s Nephrite Jade.
matte
of
fibrous
is
tremolite.
i n the continuous
variable.
The v a r i a t i o n s
Mohawk's J a d e
and
magnetite.
The
unique
very
physical
durable
such
composed
of three
aggregate
characteristics
but also
primary
than
texturally
minerals
According
i s an amphibole
series
the composition
a very
chromite,
of Nephrite
difficult
due t o
minerals
chlorite,
Jade
occurs
of
make
large
random
individual
3.
Learning
crystals.
o f 61,000 l b s / i n
2
bundles,
Jade
i s
i s
t e x t u r e i n which
tufts
and s h e a f -
granite
has a
very
(Belyk e t a l 1973),
Jade has a high d e n s i t y , about
Jade i s
minerals a l l
Nephrite
whereas
Jade
harder
Granite
accessory
(1978),
orientation,
i ta
constitute granite
compositionally.
as t w i s t e d and f e l t e d
s t r e n g t h , i n excess
steel.
and
and s e v e r a l minor
to
hardness
m i n e r a l s which
talc
m a t e r i a l t o work.
rock c h a r a c t e r i z e d by a p e c u l i a r
i n interlocking
composed
compressive
185
different
tremolite
aggregates
greater
(chrome g a r n e t )
t o the primary
a monominerallic
microfibrous
tremolite
There a r e o f t e n minor amounts o f o t h e r
material,
i n nature.
essentially
life
- ferroactinolite
of
composed
o f b e t w e e n 6 a n d 7 o n t h e Mohs H a r d n e s s S c a l e , i t i s much
i s much
crystalline
a rock
the composition
m a t e r i a l s as marble and onyx, a t a p p r o x i m a t e l y
jade
i s referred to
i sessentially
However, because t r e m o l i t e
uvarovite
about e q u i v a l e n t i n hardness
but
that
i n the colour of nephrite are primarily
and c h e m i c a l
building
At a hardness
than
including
i n t h e w o r l d , an amphibole
The j a d e
Ideally,
tremolite
this compositional variation.
in
(Jadeite) .
N e p h r i t e Jade
a p p r o a c h e s C a 2 Mg5 S i g O22 (OH)2.
mineral
recognized
i s an
high
which i s
3.0, e q u i v a l e n t t o a b o u t
l b s / f t ^ , o r more t h a n 5% g r e a t e r t h a n t h e d e n s i t y o f g r a n i t e .
- 8 -
4.
The
CUTTING, GRINDING AND POLISHING PROCESSES
physical characteristics
ground
and
generally
inert,
Therefore,
working
polished.
o f the jade
Chemistry
essentially
the following
affect
i s not very
unaffected
physical
important,
by s t r o n g
since
solvents,
characteristics
appear
jade
acids
i s
or bases.
t o be c r i t i c a l f o r
jade:
6 to 7
Hardness
Compressive
Specific
+61,000
Strength
lbs/in
2
3
a p p r o x . 3.0 ( 1 8 5 l b s / f t . )
Gravity
m i c r o f i b r o u s m a t t e - random o r i e n t a t i o n
Texture
Certainly
colour
i s a
criteria
from
an
translucency
and l u s t r e .
m u s t be t h i n
i s due t o t h e t r a n s l u c e n c y .
the
grind, cut, or polish.
jade
4.1
how t h e m a t e r i a l c a n b e c u t ,
will
aesthetic
One o f t h e r e a s o n s
viewpoint
as
f o r specifying that
However, t h i s
does
i s the
the t i l e s
not affect
how
CUTTING PROCESSES
Cutting
technologies
and techniques
1.
High pressure
4.
D i a m o n d s e t o r i m p r e g n a t e d saw b l a d e s
These
systems
materials
were
including
Manufacturers
ineffective;
abrasive
water;
lasers;
identified
metal,
are listed
overall
results.
sawing
employing
abrasive
slurries;
of various configuations.
researching
stone,
wood,
i n Appendix
was g e n e r a l l y
3.
by
l a s e r beams may h a v e
slurries
favourable
2.
investigated included:
I.
limited
industries
glass,
High
pressure
specific
unsuccessful;
and
which
other
water
cut
minerals.
was g e n e r a l l y
a p p l i c a t i o n s ; sawing
diamond
hard
s e t saws g a v e
using
t h e most
- 9 -
4.1.1
HIGH PRESSURE WATER
High
pressure
crystalline,
a
system
water
cutting
with
b y Admac , w h i c h
i s marketed
some
success
when
Flow Systems o f Kent, Washington
natural material.
that
met
has
i s
employed
used
on
has developed
i n cutting
marble,
g r a n i t e and o t h e r m a t e r i a l s .
Discussions
with
system
could
system
uses
Failure
Rod D r a u g h t o n
c u t jade
high
i t would
pressure
o f the jade
and J i m White
test
indicated
n o t be v i a b l e
water
with
cutting
that
although
on a commercial
abrasives
was a t t r i b u t e d
added
their
basis.
t o t h e water
t o thematerial's
The
stream.
hardness,
f i b r o u s n a t u r e a n d random o r i e n t a t i o n o f t h e f i b r e s .
4.1.2
LASER
T e s t work h a s r e p o r t e d l y
been c a r r i e d
on A l a s k a n j a d e e m p l o y i n g
'86)
suggest
proved
an
V
was l e s s
conducted
Flat
test
cutting
unsatisfactory.
inverted
cut
that
(ie:
were
automatic.
$150.00
p e r hour.
Vancouver,
making
the
Cut-A-Die
B.C.
complex
and l e f t
successfully
525.
internal
cuts
c o n t i n u o u s wave mode.
The k e r f
on
the surface
damage
cutting
(no s i g n i f i c a n t
on t h e s i d e
on e x i t
slabs
that
side.
and t i l e s .
cutting
a 600 w a t t
and etching
cutting
loss
rate
a
2
4 x4''
-
penetrative
damage).
There
by Arvan
T h i s machine w i l l
of
tile
using
The edges
(burned)
white
was n o s i g n i f i c a n t
and approximately
have
Royal
rate o f
o f 20 i n c h e s p e r m i n u t e
andbleached
could
a
1/8" t h i c k
sandpaper
The l a s e r
work
some s u c c e s s .
was a p p r o x i m a t e l y 0.2mm.
entered
of the
c o n t r o l l e d and f u l l y
o f 80 g r i t
t h e beam
Test
laser,
be done
w
lasers
t h e depth
residue.
CO
- Aug.
t h e shape o f
a t a charge-out
can also
c u t through
a t a cutting
t h e c u t were t h e roughness
burning
c u t using
laser
of
slag-like
Also
o f M a r k h a m , O n t a r i o met w i t h
laser
Cut-A-Die's
t o have
o f the cut) .
a glassy,
(D. A n d e r s o n
and i n t e r m i t t e n t
T h i s machine i s computer
does custom
Custom
steady
were uneven and t e n d e d
by Cut-A-Die
Zenith - Coherent E v e r l a s e
using
a t t h e bottom
than one i n c h
slabs
P e r s o n a l communications
o f jade
The c u t s
wider
f o r Mohawk
jade
lasers.
o u t by Nana C o r p . o f A l a s k a a n d B a t t e l l e
applications
perform i n t e r n a l
.5ram o f b u r n
f o r e t c h i n g and
(jigsaw)
cuts or
- 10 -
external
cats
surfaces
because
cut
on f l a t
distance
from
by t h e d i s p e r s i o n
becomes f u r t h e r
4.1.3
The l a s e r
tested
t h e l i g h t r a y must be f o c u s e d
a t a constant
limited
surfaces.
and s t r i k e
thel i g h t source.
o f t h e r a y which
n o t c u t uneven
thesurface
The d e p t h
occurs
t o be
of thecut
as thesurface
i s
t o be c u t
f r o m t h e f o c a l p o i n t o f t h e beam a s t h e c u t d e e p e n s .
ABRASIVE SLURRIES
Breton
s.p.a. o f I t a l y manufactures a r e c i p r o c a t i n g
which employs an a b r a s i v e
cuttings
and s t e e l
the
results
test
relies
stone
being
cuttings
satisfactorily
as a c u t t i n g
A detailed
on t h ea b r a s i v e
slot
also
4.1.4
shot.
c u t and/or
steel
slurry
slurry
the material
and s a w - c u t t i n g s
assist
i n thecutting
being
perforated
steel
g a n g saw
a g e n t composed o f l i m e ,
description
from Breton's experiments,
primarily
lime,
(see
o f the system
Sub S e c t i o n
dislodging
softer
mineral
than
process.
p r o b a b l y due t o t h e h a r d , f i b r o u s
under
The system
crystals
This
and thus
The system
mineral
follows
5.1).
steel.
i s recirculated
from t h e
slurry of
the mineral
failed
t o perform
nature o f the jade.
DIAMOND SAWS
T h e r e a r e e s s e n t i a l l y t h r e e s t y l e s o f d i a m o n d saws t h a t
1.
would
Disc
and
(circular)
saws o f v a r i o u s d i a m e t e r s
f o rblocking,
investigated:
slabbing,
bucking
ripping.
2.
Reciprocating
3.
B a n d saw p r i m a r i l y
Blades
were
saws p r i m a r i l y
for
for blocking
blocking
f o r a l l o f t h e above
saws
and
or slabbing.
slabbing.
are either
continuous
r i m - diamond
set or
impregnated b l a d e s , o r segmented - diamond s e t o r impregnated b l a d e s .
Diamond
cutting
cutting
industry.
technology
i s t h e most
Virtually
every
common
manufacturer
i n t h e stone
o f stone
l e a s t o n e s t y l e o f saw d e s i g n e d t o a c c e p t d i a m o n d
and mineral
cutting
blades.
equipment
has
at
- 11
The
principle
will
cut
the
behind
softer
diamond
jade
Other
physical
sawing
process, especially
process
for
crystals,
abrasive
cutting
or
cutting
the
cutting
nature of
the
texture of
granite
involves
of
jade
b e t w e e n t h e c u t t i n g medium
crystals.
tool's
softer
is
the
of
affect
t o be
by
a
harder
the
saw
upon
the j a d e .
hardness
this
cut.
The
of
meets
The
cuttings
jets
the
are d i r e c t e d
jade.
Most
of
r e l y on
between
material
t h e b l a d e and
b l a d e and
non-abrasive
and
r a t h e r than a s s i s t i n g ,
into
e x c e p t i o n o f t h e b a n d saw
t h e saw
are
the
material
The
the
cutting
systems,
tend
The
f l u s h e s t h e c u t t i n g s o u t o f t h e saw
water
cut.
the
diamond
b l a d e m u s t be
to
able
dislodge
plug
the
process.
near
where
with
the
possible
high
pressure
h i g h s p e e d s f o r t h e b l a d e s and
being cut.
and
difference
the c u t t i n g
c u t aimed a t o r
typical
individual
hardness
saw
7.
mechanical
The
cuttings.
the
10,
b e t w e e n 6 and
"plucking-out"
primarily
(diamond) and
do
the m a t e r i a l
material
based
a hardness
hardness
t h a t comprise
surface inhibiting,
Commonly w a t e r
blade
a
has
i s t h a t diamonds,
the randomly o r i e n t e d matte o f f i b r o u s n e p h r i t e r a t h e r than
individual
cutting
which
besides
the m i n e r a l s
for
technology
granite
characteristics
process
to sever
sawing
-
the
saw
a c t s as a c o o l a n t f o r
- 12 -
4.2
The
All
GRINDING AND POLISHING PROCESSES
physical
c h a r a c t e r i s t i c s o f the jade
the grinding
diamond
tools
and
and h a r d
e s s e n t i a l l y one o f two
The
Lapping using
2.
Grinding
Mohawk
of
rotating
plate
lapping
is
a
sanding
discs
polishing/lapping
and
the material
involve
working
o r powder.
i s worked.
the jade
The
with
techniques are
polishing
grits.
using
diamond
tools
and
sandpaper
type
grit.
System
addition
grit
techniques
how
types:
1.
diamond
polishing
affect
employs
a
lapping
grit
slurry.
The
spins
on t h e t i l e
and p o l i s h i n g
slurry
surface
floods
process
the t i l e
and t h e t a b l e
and p o l i s h i n g p r o c e s s u s e s two d i f f e r e n t g r i t
which
surface
spins.
sizes.
relies
on
while
a
The t w o s t a g e
The f i n a l
polish
dependent upon t i m e f o r e a c h s t a g e .
The c o m m e r c i a l s t o n e g r i n d i n g
universally
heads,
employ
which
combination
diamond
gradationally
grind
grinder/polisher
and p o l i s h
has been
o f head
set tool
a n d p o l i s h i n g m a c h i n e s made i n Germany a n d I t a l y
on
diamond s e t t o o l a l s o
(tool)
finer
the t i l e
recommended
pressure
the surface
oscillates.
diamond
set tools
surface.
f o r jade.
on t h e t i l e
t o be
polished
mounted
Generally
This
an e i g h t
technique
surface,
and on
i n rotating
relies
head
on a
the r o t a t i o n of the
some
machines
the
- 13 -
5.
T I L E MANUFACTURING PLANTS
Many
manufacturers
contacted.
fully
high
pressure
manufacturers
and
slabs.
1.
specialty
of a multifaceted
were
asked
There were
The m a j o r ,
integrated
2.
The
3.
After
cutting
tests
With
systems,
the exception o f
only
the
f o r t h e manufacture
plant,
integrated
o f jade
tiles
decision:
whereas
d i d n o t have
two
properly
could
the
supply a properly
manufacturers
sized
equipment
of
f o r an
equipment
manufacturers
could
not
supply
the
service
from s m a l l ,
t o determine
foreign
but expected
e q u i p m e n t m a n u f a c t u r e r s was
t o be poor
i n comparison
to the
firms.
small
training
5.
equipment
complete,
f o r one o r perhaps
system.
equipment manufactures
sized
who p r o d u c e
were
plant.
sales
larger
The
and
equipment
t o d e s i g n an e n t i r e p l a n t .
difficult
4.
t o perform
specialized
expertise
exclusively
s e v e r a l reasons f o r t h i s
engineered,
polishing
manufacturers
manufacturing
and l a s e r
integrated
specialized
and
a n d many more m a n u f a c t u r e r s , p r i m a r i l y i n
equipment
tile
water
grinding
equipment
equipment packages
who p r o d u c e
seqments
cutting,
are several
integrated
Italy,
the
There
of
companies
assistance
Only
the larger
test
work
generally
could
except a t a high
not offer
installation
cost.
equipment manufacturing companies c o u l d
required
t o determine
i f a certain piece
a n o v e r a l l p l a n t d e s i g n was v i a b l e .
and
perform the
o f equipment o r
- 14
From t h e
the
short l i s t
necessary
companies
of
tests
agreed
manufacturers
companies
and/or
to
also
identified
supply
perform
agreed
a s s i s t a n c e on
c o m p a n i e s who
performed
Mohawk d e l i v e r e d
require
that
researched
the
jade
The
numbers
most
and
manufacturers
of
and/or
be
of
to their
complete
along
with
manufacturers
names
equipment
a
are
shipped
to
do
after
and
two
full
the
preliminary
comparisons
include
such
because
such
performed
are
as
Carl
to
i f their
trials,
full
illustrated
items
as
c o s t s were
company
incurred.
tests
take
in
best
is
economic
Table
chosen
provided
as
and
on
Appendix
of
I.
The
by
preferred,
The
for
and
six
supplying
Gregori
Hensel.
after
designs
Two
of
i t
was
agreeing
looked
viable
comparisons.
Two
The
costs
results
of
the
listed
do
not
training,
a l l manufacturers.
these
not
their
phone
I.
jade
and
i f
manufacturer's
scale testing
jade.
costs,
and
the
equipment
set-up
A l l
did
firms; Breton,
systems
the
a l l
candidates
evaluations
test
transportation,
not
these
charge
and
addresses,
Meyer, L o f f l e r
delivery
systems
scale
on
tool
descriptions of
names,
German c o m p a n i e s d i d p r e l i m i n a r y b e n c h
scale
manufacturers
which
t h r e e German f i r m s ;
refused
six
of
a t no
of
brief
listed
identified
tests
list
and
companies
line,
none
facilities
and
Italian
perform
Several
test
i n t e g r a t e d equipment i n c l u d e d t h r e e I t a l i a n
the
plant.
the
appropriate
Pedrini
production
eventually
to perform
A
i n Appendix V,
contact
to
to the equipment manufacturers.
charge
returned.
important
but
able
f r o m Mohawk f o r t e s t w o r k , a l t h o u g h s e v e r a l
technology
free
being
tile
specify
tests,
t e s t work a g r e e d
jade
is detailed
businesses.
telex
the
tool
as p o s s i b l y
integrated
perform
companies were g i v e n j a d e d i r e c t l y
contributed
an
tests
to
-
additional
taxes
etc.,
Irrespective
costs
would
of
be
2
TABLE I - PLANT COMPARISONS (1,000 FT /MO. - 4" X 4" TILES)
PLANT
COUNTRY OF
ORIGIN
T I L E SIZES PRODUCED
4x8
6x6
8x8
12x12
4x4
SLABS
TILE
THICKNESS
(4" x 4")
BRETON
ITALY
X
X
X
X
X
X
3-5mm
GREGORI
ITALY
X
X
X
X
X
X
3-5mm
% YIELD
(*3)
FACTORY
FROM
PRODUCTION SUPPORT
RAW
COSTS
& PARTS
BOULDERS
PER F T
AVAILABLE
2
30%
Approx.
PLANT
AREA
(FT )
WATER
REQUIREMENTS
(LITRES/MO.)
4.9 m i l l i o n
2
$32.40
FAIR
7,800
$38.15
POOR
7,500
N/A
25%
PEDRINI
ITALY
X
X
X
X
X
X
3-5mm
Approx.
5
$35.15
POOR
7,400
25%
W. GERMANY
X
X
X
X
X
X
3-5mm
50%
$22.55
GOOD
4,800
LOFFLER
W. GERMANY
x
x
x
x
x
x
3-5mm
22%
$34.25
F A I R TO
6,500
( S l a b s m i n . 10mm)
W. GERMANY
X
X
X
MOHAWK (*1)
U.S.A. & CAN.
x
x
U.S.A. & CAN.
x
x
(Current
GOOD
million)
(Est.
approx.
million)
1.5 m i l l i o n
N/A ( E s t .
approx.
3 million)
3-5mm
40%
$26.52
GOOD
5,200
x
3mm
27%
$97.68
FAIR
3,150
1 million
x
3mm
35%
$57.95
FAIR
4,800
3 million
X
X
X
2.9 m i l l i o n
Plant)
MOHAWK
(*D
N/A
5
CARL MEYER
HENSEL
(Est.approx.
2
- Based on a c t u a l p r o d u c t i o n o f 225 f t p e r month.
(*2) - E x c l u s i v e o f f r e i g h t , t a x e s , d u t y , s e t - u p c o s t s , e t c . (Complete $CDN. - F.O.B. O r i g i n ) . .
(*3) - Labour, t o o l s ,
jade.
TABLE I
(cont'd)
NO. OF
POWER EMPLOYEES
PLANT
BRETON
450 h p
PRODUCTION
RATE
(4"x4" TILES)
+2,000 f t
2
PLANT
SET-UP &
TRAINING
PROGRAM
BACKING
REQUIRED
FOR
PRODUCTION
TOOLS
AVAILABLE
TEST
WORK
SUCCESS
(*2)
EQUIPMENT
COSTS
YES
YES
FAIR
PARTIAL
$773,300
650 kw
GREGORI
740 h p
R e q u i r e s b o u l d e r s be encased i n g r o u t
Maximum w i d t h o f s l a b 4 0 "
7-8
510 kw
PEDRINI
MISCELLANEOUS
Estimate
NO
1,500-2,000
YES
FAIR
NO
$674,600
S l a b s maximum w i d t h o f 4 0 "
2
ft /Mo.
620 h p
High water consumption
NO
YES
FAIR
NO
$910,750
430 kw
S l a b maximum w i d t h 2 1 "
B l o c k saw s t e p c u t s , n o t s i n g l e
Allowing
CARL MEYER
250 h p
4-5
2
1,720 f t / M o .
YES
NO
GOOD
YES
$742,000
200 kw
LOFFLER
thinner blades
- Can produce 62" wide s l a b s
- Bandsaw o p e r a t e s w i t h segments m i s s i n g
261 hp
A p p r o x ima t e l y
210 kw
1,500
YES
YES
FAIR
NO
$650,000
Low p r e s s u r e
polisher
2
ft /Mo.
S l a b s u p t o 1 0 8 " w i d e b y 10mm t h i c k
can be c u t
HENSEL
2
5 0 hp
5
1,650-1,850
5
225 f t / M o .
2
ft /Mo.
YES
YES
GOOD
PARTIAL
$510,000
- Cut 18"xl2"
N/A
NO
GOOD
YES
$216,550
- S l a b s maximum w i d t h 2 1 "
N/A
NO
GOOD
YES
$461,550
s l a b maximum
200 kw
MOHAWK
65 h p
2
48 kw
MOHAWK
200 h p
145 kw
pass
14
2
1,125 f t / M o .
(total
including current plant capital)
TILE C O S T V S . J A D E
$ 12.00
h-
R E C O V E R Y - T A B L E III
—
^
+
1
/
/
/
$ 11.00
L_
1
1
°
/
$ 10.00
/
:
-!
IL
_
i
i
/
—
i
i
:
$ 9.00
i
j
i
;
i
i
,
I
i
i
1
i
i
i
i
i
/\
I
/
i
|
]
:
,
\
1
I
$ a oo
/
1
\-
/
/
$7.00
/
i
/
/
$6.00
1
1
!
!
i
>
/
/
i
/
/
/
/
/
$5.00
/
1
I
/
$4.00
1
$3.00
h
100
90
•
*
80
—
1
—
70
JADE
Jade c o s t - $ 1 . 5 0
Tile « 1/8"
per lb.
60
50
RECOVER Y
thick
40
,,
A
30
20
[0
- 15 -
5.1
BRETON s . p . a .
Breton's
block
multiblade
Another
saws
sawing
gang
saw u s i n g
possible
can only
depth
of
technology
saw t y p e
produce
blade)
limitations.
a
i s a vertical,
lime
slurry
oscillating
and s t e e l
shot
i s a m u l t i b l a d e diamond d i s c
slabs
whereas
less
the
The p o l i s h i n g
than
one-half
reciprocating
technique
schematic
detail
of Breton's
system
i s essentially
i s illustrated
saw.
does
r e s e a r c h e d w i t h t h e e x c e p t i o n o f C a r l M e y e r who u s e s
A
as a c u t t i n g
the blade
saw,
or reciprocating,
agent.
However, t h e d i s c
diameter
not
(cutting
have
t h e same
the
same
as the o t h e r s
a lower p r e s s u r e p r o c e s s .
i n Figure
2 and d e s c r i b e d i n
below.
STEP 1
Place
the jade
direction,
grout)
boulders
i n a box-like
pack as t i g h t l y
jacket.
as p o s s i b l e
form.
Orient the boulders
i n t h e same
and encase i n a cement and sand
E a c h b l o c k t o be a p p r o x i m a t e l y
(soft
1000x2000x1000mm.
STEP 2
Load
blocks
reciprocating
cutting
under
gang
band,
gang
slurry
of steel
blocking
saw was
shot
t o break
other
were
tested
and
tested.
cut
into
The s t e e l
and l i m e f a i l e d
r a t e , t h e blades tended
two saws
saw
A
vertical
p e r f o r a t e d bands
and a
t o c u t t h e j a d e a t an a c c e p t a b l e
a n d t h e minimum s l a b
the o s c i l l a t i n g
slabs.
t h i c k n e s s was 10mm.
Masterbreton
HG
and
The
rectilinear
B o x e r b r e t o n HSE.
A
reciprocating,
diamond
segmented
blade,
gang
saw, t h e " D i a b r e t o n - H S W " h a d
t r o u b l e w i t h s e g m e n t s t e a r i n g o f f , a n d was c o n s i d e r e d
A
large
was
diameter
segmented
circular
some t r o u b l e w i t h s e g m e n t s b r e a k i n g o f f .
still
h a d t o be e n c a s e d
vertical
blades
automatically,
uses
diamond
and one
(disc)
The O r t o b r e t o n
horizontal
cut-off
sequence.
a p p r o x i m a t e l y 425 1 / m i n . o f w a t e r
saw p e r f o r m e d ,
I t was f o u n d
i n grout.
i n a step cutting
unacceptable.
blade
This
but there
that the boulders
4EG o r 2EG w i t h
will
system,
c u t up
t h e most
to 8
up t o 8
blocks
successful,
a n d h a s a t o t a l o f 1 8 2 . 5 h . p . (140 k w ) .
BRETON
JADE
SYSTEM
and
2
F I G U R E
GROUT
STEP
STEP I
2
GROUT
STEP
4
-ACRYLIC
or
FIBERGLASS
STEP
9
STEP
3
STEP
7
- 16 -
STEP 3
Apply
acrylic
cement
sheet
o r chop
fibreglass
t o t h e back
o f each
s l a b o f j a d e and
aggregate.
STEP 4
Polish
the slabs
spindle
using
grinding
polishing.
a L e v i b r e t o n KG 4 0 / 0 1 2 .
heads
f o r dressing
I t can p o l i s h
up
This polisher
(lapping)
the slab
t o 200 f t ^ p e r h o u r .
has 7 v e r t i c a l
and
This
2
heads f o r
machine
uses
250
1/min. o f w a t e r a n d h a s a t o t a l o f 140 h . p . ( 1 0 5 k w ) .
STEP 5
A
jig-saw
and
i s used
cement
(manual)
slabs.
This
t o c u t the polished
involves cutting
only
jade
slabs
t h e cement
o u t from
grout
the jade
encasing
the
jade.
STEP 6
Strips
a r e then
transversal
are
h.p.
rectifying
required
strips
c u t from
holding
t h e rough
saw.
This
shaped
jade
saw w i l l
350mm d i a m e t e r
diamond
up t o 2000x400mm a n d s l a b s t o 7mm
slabs using
handle
up t o 7 b l a d e s
d i s c blades.
thick.
a Breton
This
This
190 ADR
but only
saw w i l l c u t
saw h a s a t o t a l
(13 kw) f o r t h e s p i n d l e m o t o r s , p u s h m o t o r a n d r o l l e r
2
o f 17.5
motor.
STEP 7
The
tile
diamond
cutting
disc
600x300mm
conveyor
saw DXS/5 c u t s
blade
(24"xl2").
capable
The
t o the chamfering
of
the jade
squaring
tiles
machine.
strips
tiles
a r e then
into
with
a
transported
tiles
using
maximum
by
a
single
dimension
motorized
of
roller
- 17 -
STEP 8
The
tile
edges a r e chamfered
and p o l i s h e d by a C h a m f e r i n g
Breton Model
IBS/28
h a v i n g a t o t a l o f 6 h.p.
STEP 9
The
t i l e s a r e washed, d r y e d ,
The
Breton
process
s t e p where j a d e
high
i n s p e c t e d and packaged.
h a s some
flaws or d i f f i c u l t i e s i n the primary
l o s s e s and t o o l
p r e s s u r e s employing
breakage
other
methods because cement a s w e l l
i s considered
production
required
allow
rate
of
t o operate
production
month based
c o u l d be h i g h .
a multi-movement head
cause
service
of thin
failure
slabs.
the
1,000
best
f t
the plant.
to increase
The p o l i s h i n g
2
as jade
of
a
An a d d i t i o n
t o more
o n a 40 h o u r w o r k week.
than
The p o l i s h e r
t o l a p the slabs.
process
total
firms
of
Breton
f t
This
could
seven
2
people
At
would
two p e o p l e
o f 4x4 i n c h
than
back-up and
researched.
o f approximately
2,000
r e l i e s on
i s more e x p e n s i v e
i s polished.
the I t a l i a n
p e r month
(blocking)
a
be
could
t i l e s per
- 13 -
5.2
GREGORI s . p . a .
Gregori
slab
i s an I t a l i a n
and
employs
plant
tile
production
multi-blade
including
declined
conveyors
diagram
o f a complete
equipment.
circular
t o perform
schematic
manufacturer
any
o r d i s c saws.
and
other
test
of their
Their
primary
o f marble
block
after
handling
the jade
i s illustrated
and g r a n i t e
sawing
They do p r o v i d e
materials
cutting
system
line
technology
a fully
designed
devices.
arrived
Gregori
i n Italy.
i n Figure
3
and
of
drying
A
described
below.
STEP 1
The
blocks
would
preparation
Bufalo-mg,
600
have
f o r sawing
i s capable
t o be
using
secured
a
circular
mm.
Minimum
standard
This
cut slabs
step
of slabs
o f 380 v o l t s .
requires
(disc)
a
saw.
blades
grout
This
in
saw, a
i n diameters
from
350-600mm i n d i a m e t e r .
This
a maximum d i m e n s i o n o f 3 5 0 0 x 1 8 0 0 x 1 8 0 0
i s estimated
t o be
8mm.
T o t a l power r e q u i r e m e n t
carriage
t r a n s p o r t e d by b r i d g e c r a n e
with
quick
blocking
c u t - o f f blade
from b l o c k s
thickness
voltage
bed
o f c a r r y i n g up t o 19 v e r t i c a l
t o 1200mm p l u s o n e h o r i z o n t a l ,
machine w i l l
in a
f o r the
o r some s i m i l a r
raw
blocks.
device
This
saw
has a
i s 250 h . p . (184 kw) .
The
cut slabs
to a deposit
are
area.
STEP 2
The
slabs
which
This
i s capable
machine
strips
wide) .
The
strips
a n arm c r a n e
the Ghepard,
t h e two o p p o s i t e
are required,
A 500mm b l a d e
volts.
up w i t h
of feeding
squares
i f tiles
380
slab
are picked
is
and s t a c k e d
automatic
squaring
tilting
sawing
s i d e s o f a s l a b and c u t s
to the desired
normally
on a
used
dimension
i n t h i s machine.
(ie:
device
machine.
the slab
4",
Standard
6"
into
o r 12"
voltage i s
Power d r a w i s 24 h . p . ( 1 6 . 6 k w ) .
(or slabs)
deposit
area
travel
along
where a c r y l i c
a free roller
sheet
(slabs) are f e d into the c a l i b r a t i n g
c o n v e y o r band t o t h e f i n i s h e d
i s applied.
machine.
From
this
area
the s t r i p s
GREGORI
SYSTEM
3
F I G U R E
STEP
7
- 19 -
STEP 3
The
Polaris
620/30,
desired
thickness.
(slabs)
would
fact
i t may
calibrating
I t i s probable
require application
be
necessary
calibrating
machine
total
o f 76.5 h.p.
power
machine
motorized
roller
polishing
machine.
that prior
this
vertical
(53 kw) .
conveyor
the s t r i p s
backing,
backing
s p i n d l e diamond
and/or
machine
with
a
strips
motorized
strips
2) a n d i n
t o Step
head
t o the
the jade
(see Step
prior
The c a l i b r a t e d
band
(slabs)
to calibration
o f an a c r y l i c
to apply
has three
grinds
2.
The
grinders with
then
tilting
travel
device
a
by a
to the
STEP 4
A Vega
the
620/8+1, p o l i s h i n g
final
polish
on
the jade
installed
214 h . p . (157 kw) .
band
another
to
transversal
motorized
cutting
band, i f t i l e s
strips
8 planetary polishing
(slabs).
The s t r i p s
roller
o f the s t r i p s
travel
conveyor
and a l o n g
r a t h e r t h a n s l a b s a r e t o be
This
along
and
another
heads
machine
a free
then
completes
has a
roller
to
a
motorized
total
conveyor
machine
roller
for
conveyor
produced.
STEP 5
A
Mini-Super
controls
cuts
Special,
automatic
the s t r i p s
squaring
into
the desired length
carries
a 700mm d i a m e t e r
strips).
This
machine
installed
H.P.
(18 kw) , a s s t a n d a r d .
chamfering
machine
The
complete
with
(transversal
circular
tiles
cutting
blade
a r e then
hydraulic
of the
a n d h a s 23.5
conveyed
to the
step.
STEP 6
An
Orion,
automatic
These
chamfering
edge
machine
and c o r n e r
chamfers
polishing
two m a c h i n e s i n tandem w i l l
a total
installed
t h e edges
machine
finish
chamfer t i l e s
27.25 H.P. (20 k w ) .
of the t i l e s
t h e edges
and a
Sirio,
o f the
tiles.
o f minimum 8ram t h i c k , a n d h a v e
- 20 -
STEP 7
The
tiles
(to
conserve
grooving
are f e d along
space),
machine
moved a l o n g
to
which
another
a motorized
another
grooves
roller
roller
conveyor
motorized
the bottom
band,
roller
a motorized
conveyor
of the t i l e s .
and
into
The t i l e s
conveyor band t o t h e washing and d r y i n g
curve
the
a r e then
sequence.
STEP 8
The
final
step
conveyor band
i n v o l v e s moving
the completed
t o t h e i n s p e c t i o n and p a c k i n g
tiles
along
a motorized
bench and f i n i s h e d
product
roller
storage
area.
Some G r e g o r i
taken
saws
a r e known
that the e l e c t r i c a l
standards.
The c i r c u l a r
losses
the c i r c u l a r
in
from
the form
with
single
blade
blades
will
missing
failure
to
o f two p e o p l e
1,500 t o 2,000 f t
2
a r e known
to require
and c a l i b r a t i n g
(sawdust) .
occurs.
month o f 4 x 4 i n c h t i l e s
addition
saws
Circular
and m u l t i - b l a d e
be 3 t o 5mm
Canada.
Care
components and w i r i n g conform t o Canadian
sawing
of cuttings,
segments
t o be i n u s e i n E a s t e r n
I n order
thick.
gang
consume
saws
can ruin
t o c u t 3-4mm t h i c k
The G r e g o r i
plant w i l l
slabs
tiles
produce
and t h e
a l o t of
saws do n o t o p e r a t e
allow production
p e r month.
o f 4x4 i n c h
jade
very
well
i f even
a
(slabs) the
2
1,000 f t p e r
b a s e d o n a 40 h o u r work week a n d s e v e n e m p l o y e e s .
should
be
electrical
a l o to f water
stages
must
tiles
The
to increase
-
5.3.
21
-
PBDRINI s . p . a .
Pedrini
i s an
Italian
granite
slabs
and
tiles.
and
cutting slabs
and
polishing
to
but
may
required.
Equipment
each
step
below
conveyors
and
estimated
studying
extensive
a
the
saws f o r
jade
redesign
j a d e p l a n t was
illustrated
cranes
costs of
for production
if
which
not
i n Figure
would
be
agreed
thin
jade
provided.
The
includes
necessary
for
a
marble
raw
that
boulders
their
and
cutting
slabs
were
w e r e made a v a i l a b l e
equipment l i s t e d
such
items
complete
t h i s equipment between the major p i e c e s
and
to perform c u t t i n g
blades
the
4,
of
blocking
decided
recommendations f o r working
of
and
equipment
Pedrini originally
after
require
o v e r a l l design
of
They employ c i r c u l a r
dimension.
tests
technology
but
manufacturer
as
in
roller
plant.
The
i s $85,000.
STEP 1
This
step
securely
is
a
slices
to allow
circular
Block-cutter
blade
until
into
saw
along
a
predetermined
enough
crane.
slices
The
The
with
a
width
similar
backing
slab thickness
depth
cut
slabs
3,200ram.
w o u l d be
of
blocking
totals
the
and
The
cut-off
by
266
slabs.
8mm
The
by
deeper
the
operator
h.p.
to
Pedrini
and
to
be
anchored
recommended m o d e l
single horizontal
Several
the
move
have
single vertical
useful stroke
would
i n excess of
saw.
i s reached.
removal
the
would
progressively
allow
slabs
to
block
$202,140.
cut
to
inches),
i s applied
the
making
power
The
The
single vertical
require
machine
of
at
bridge
are
a p p r o x i m a t e l y 550mm (21
cutting
slabs.
proper operation
M o d e l M535, p r i c e d
diamond d i s c .
of
block
bridge
travels
desired,
a
diamond
cuts
such
cuts
are
employing
cutting
s t a t i o n where
indicated
that
b l a d e w i d t h more t h a n
the
made
mounted
some
depth
i s a b o u t 3,850mm and
a
disc
until
horizonatally
Maximum
blade,
5mm.
is
useful
acrylic
the
type
or
minimum
PEDRINI
I
SYSTEM
4
STEP
X
FINISHED
F I G U R E
PRODUCT
6
- 22 -
STEP 2
After
slabbing
and a c r y l i c
would c a l i b r a t e t h e s l a b s
$154,170.
This
and
vertical
three
control
total
machine
sheet
to the desired
required
thickness.
comes c o m p l e t e w i t h
spindle
grindling
and automatic u n i f o r m
installed
a p p l i c a t i o n a Model
122.75
machine
A
motorized
digital
roller
machine
i spriced a t
conveyor a t t h e feed end
electronic
t o o l consumption adjustment.
h.p.
t o move t h e s l a b s
This
a roller
heads,
M541, g r i n d i n g
thickness
The machine h a s a
conveyor
band
would
be
t o the p o l i s h i n g machine.
STEP 3
The
Model
M536, p o l i s h i n g
machine
with
up t o 17 v e r t i c a l
spindle
heads and p l a t e s would p o l i s h t h e s l a b s .
Probably
a nine
slow
polish.
The n i n e
speed
would
accomplish
p r i c e d a t $294,840.
This
c o n v e y o r w o u l d be r e q u i r e d
the desired
polishing
head machine
run at
head
polisher i s
machine h a s a t o t a l power o f 138.5 h.p.
A motorized
t o move t h e p o l i s h e d
slabs t o the next
step.
STEP 4
A
Model
(strips)
single,
M539
cross
cutting
to the desired
350mm d i a m e t e r
length
diamond
a n d t o w i d t h s o f 510mm;
feed
the t i l e s
machine
priced
a t $24,390
t o produce the f i n a l
disc will
t o t a l power
i s
cut tile
10.5 h.p.
would
c u t the slabs
dimensioned product.
lengths
This
f r o m 125mm t o 800mm
A motorized conveyor would
t o the chamfering machine.
STEP 5
The
Model
M538/G-3, c h a m f e r i n g
edges, grooves t h e t i l e s ,
packaging.
total
This
44.25 h . p .
machine
machine
washes,
bevels
the t i l e
blow d r i e s and b u f f s
i s priced
a t $150,210.
A packaging table i s included
edges,
polishes the
the finished t i l e s f o r
A l l motors
for this
as p a r t o f t h i s equipment.
step
- 23 -
P e d r i n i d i d n o t quote on a p l a n t
slab
manufacturing
would
be
tiles
and
tiles.
per
capable
the
o f 4x4
production
addition
would
reduce
of
between
The
and
considered
an
jade
the plant
extra
jade
this
tiles
would
equipment
4,000
5,000
2
f t
would
require
approximately
added
c o s t o f equipment
cost
of
At a production
approximately
s i x people
including
m a c h i n e s w o u l d be a b o u t $ 9 1 0 , 7 5 0 .
The
per
4x4
3,000
tile
Pedrini
month
of
produce
upon an 8 hour
a t an
2
p e r month
based
of people.
tiles
f t
equipment
jade, thus g r a n i t e
appropriate.
estimated
approximately
inch
capital
was
producing
t h e number
m o n t h o f 4x4 i n c h
plant.
of
I t i s estimated that
month
full
slabs
equipment
f o r manufacturing
and
plant
of
granite
inch
granite
t o 3,500 f t
d a y , 5 d a y week.
nine
people,
of
1,000
roller
$98,000
f t
w o u l d be r e q u i r e d
turntables,
At
although
approximately
rate
2
2
per
i n the
conveyors
- 24 -
5.4
CARL MEYER
T h i s W e s t German m a n u f a c t u r e r
o f stone
cutting
and p o l i s h i n g
t h e most c o m p r e h e n s i v e s e r v i c e o f any m a n u f a c t u r e r
and
polishing.
They p r o v i d e c o m p l e t e e n g i n e e r i n g
are
considered
superior
f o r equipment
performance.
Carl
specifications,
estimated
recommended
system
blocking, cutting,
expects
t o have
continuous
Meyer
is a
where
tool
five
complete
production
locations
provided
polishing
a
very
costs,
step
approached
technical
detailed
water
sequence
using
primary
line
set-up
Test
equipment
work
to-date
i s operating.
system i s d e s c r i b e d below and i l l u s t r a t e
overall
on
plant
consumption.
and s l a b s and chamfering
by December
and
information
five
cutting
support and
support
a n d power
provides
f o rtest
and p l a n t d e s i g n
tiles
testing.
their
design,
machines
Their
machines f o r
tiles.
Carl
Meyer
o f 1986 f o r f u l l
scale
was c o n d u c t e d
Details
on
at several
the Carl
Meyer
i n F i g u r e 5.
STEP 1
Carl
Meyer
manufactures
diamond d i s c
fully
to
automatic,
any d e s i r e d
uses a t l e a s t
is
This
tool costs
saws
t h i c k n e s s making
30 p e r c e n t
results
close
than
and c a n o p e r a t e
i n low jade
a c u t or during
from
This
diamond d i s c
types
c u t slabs as t h i n
slabbing
463K.
a
This
a s 4mm a n d up
and b l o c k i n g
saw.
segments m i s s i n g
It
The saw
from the
cutting
and s u b s t a n t i a l l y
lower
or circular
( d i s c ) saws) t h a n
other
The
allows
does
band
does
the f i r s t
not require
not deflect
c u t t o be
blades.
1.
W i l l c u t b l o c k s up t o 2200mm l o n g a n d 1600mm h i g h
2.
Sawblade k e r f l o s s
when
started
regular "tensioning"
i s a summary o f t h e t e c h n i c a l d a t a f o r t h i s saw:
i s 4mm
including
a n y e q u i v a l e n t b l o c k i n g saw.
slabbing.
The band
saw
bandsaw, M o d e l
w i t h diamond
losses
cutting.
edge.
f o r l a r g e diameter
following
or
several
unique
i t an i d e a l
l e s s water
f o r blocking
t o the boulder
necessary
their
( e s t i m a t e d a t 1/2 r e c i p r o c a t i n g
designed
initiating
recommending
tested
diamond segment bandsaw, w i l l
q u i e t , low pressure
band.
The
saw b e f o r e
and a c t u a l l y
CARL MEYER
STEP 5
SYSTEM
r > e u
- 25
3.
Will
cut
1.2
approximately
4
Production
to
5.
3200
month
to
7.
Space r e q u i r e d -
8.
U s e s 100
9.
Foundation
10.
Price
per
day
with
jade
$26.50 p e r m
Power r e q u i r e m e n t
f t
2
per
hr.)
This
basis
the
(5 d a y
translates
8 hour per
day
work week c a n
addition
of
a
week.
be
second
to
expanded
turntable
$30,000).
cut
6.
(12
p e r month b a s e d on a 5 d a y ,
per
Tool
at
2
hr.
shift
cost
estimated
per
a one
2
(approximate
costs
2
2000 f t
on
f t
m
-
(diamond
2
and
band
is
2
(16
kw).
7.5m
long
5.0m
high
4.5m
wide
l i t r e s of water per minute
(IV
water
line).
m deep c o n c r e t e on e a c h s i d e o f
F.O.B. W e s t Germany
consumption)
($2.50 p e r f t ) .
i s 21 h.p.
r e q u i r e s 1.6
segments
including
pallets,
saw.
o i l s y s t e m and
other
extras
$415,000.
STEP 2
This
step
squares
diamond d i s c
blades
which
motorized
Bucking
will
the
Saw,
cut
to
r o l l e r conveyor
1.
Power t o t a l
2.
Requires
3.
C u t s 20
4"x4"
up
i s 6 h.p.
s l a b s and
produces
M o d e l 442.
This
a
depth
to Step
(4.4
of
3.
70
strips
saw
to
will
120mm.
Technical data
up
t o 2000x1200mm u s i n g
accept
The
300,
350
strips
f o r t h e saw
or
a
400mm
move a l o n g
a
are:
kw)
6 a t u o f compressed a i r
linear
metres per
hour.
This
i s approximately
16
tiles
4.
Tool c o s t s are estimated
5.
Price
a t $10.50 p e r m
i n c l u d i n g c o n v e y o r and
2
2
($1.00 p e r f t )
conveyor d r i v e $17,000.
f t
2
per
hour
of
- 26 -
STEP 3
The
slabs
spindle,
(strips)
low pressure
conveyor.
any
are polished
The h i g h
i n this
p o l i s h e r , Model
speed heads w i l l
b a c k i n g on t h e s l a b s .
2.
Tool
3.
Machine w i l l
can
4.
l a p and p o l i s h 5 m
be a d j u s t e d
result
a t $8.40 p e r m
according
i n a tool cost
2
an e i g h t
2
with
head,
vertical
a 6 metre
a n d p o l i s h t h i n (3mm) s l a b s
D e t a i l s on t h i s machine
T o t a l power i s 120 h . p . (90 k w ) .
estimated
using
306 G/8, c o m p l e t e
grind
1.
costs
step
t o t h e whole
2
) .
2
(52 f t / h r . ) ,
line
without
include:
($ .80 p e r f t
p e r hour
long
production
but the feed
rate
rate
which
should
step
i f tiles are
reduction.
Machine, i n c l u d i n g conveyor
i s p r i c e d a t $133,000.
STEP 4
A motorized conveyor w i l l
desired
rather
cutting
circular
into tiles.
than
convey t h e p o l i s h e d
slabs.
diamond
The machine
saw, M o d e l
T h i s machine w i l l
meters o f r o l l e r
conveyor
hold
strips
at this
452, used
four
and an e x t r a
to this
step
i s a multiblade
f o r cutting the polished
crossstrips
d i s c b l a d e s a n d comes c o m p l e t e w i t h
transferable
blade
(disc) shaft.
2
This
machine:
1.
Will
ft
2
c u t 80 r u n n i n g
metres p e r hour
which
translates t o approximately
40
p e r hour o f 4"x4" t i l e s .
2.
Has an i n s t a l l e d
30 h . p . (22 k w ) .
3.
W i l l have t o o l c o s t s
4.
C o s t i s $30,000.
estimated
a t $1.00 p e r f t
2
2
($10.50 p e r m ) .
STEP 5
After
the t i l e s
Meyer's
Model
are dimensioned
390 g r o o v e s
i n Step 4 a f i n i s h i n g
and c a l i b r a t e s t h e t i l e ,
edges and then washes, d r i e s and b u f f s
complete with
machine s i m i l a r t o C a r l
bevels
the f i n i s h e d t i l e s .
and p o l i s h e s t h e
T h i s m a c h i n e comes
a t u r n t a b l e so t h a t a l l f o u r edges a r e chamfered and p o l i s h e d .
- 27 -
D e t a i l s f o r t h i s machine a r e as f o l l o w s :
1.
T o t a l i n s t a l l e d power
2.
Tool
per
3.
costs
inch).
Ninety
are estimated
n
Fora 4 x4
linear
production
i s 27 h . p . (20 k w ) .
n
a t $0.21 p e r r u n n i n g
tile
t h e c o s t i s $0.08 p e r t i l e
feet of t i l e
r a t e o f 7.5 f t
2
metre o f t i l e
edge
p e r hour
o r $0.78 p e r f t
c a n be p r o c e s s e d .
p e r h r . f o r 4"x4" t i l e s
e d g e (0.5C
This
o r a b o u t 1300 f t
2
.
i sa
2
per
month.
4.
Equipment c o s t q u o t e d a t $82,000.
Carl
Meyer
cranes,
estimated
equipment
costs
e t c . w o u l d be a n a d d i t i o n a l
comparable t o the other manufacturers
Detailed
power
cost
estimates
C a r l Meyer f o r a 1000 f t
2
between
$65,000
machines
bringing
f o ra similar
were p o s s i b l e from
83 h r s .
p e r month x
16 kw =
1328 kwh
STEP 2:
63 h r s .
p e r month X
4.4 kw =
277 kwh
STEP 3:
20 h r s .
p e r month X
90 kw =
1800 kwh
STEP 4:
25 h r s .
p e r month X
22 kw =
550 kwh
STEP 5:
133 h r s .
p e r month X
20 kw =
2660 kwh
MISC:
133 h r s .
p e r month X
10 kw =
1330 kwh
TOTAL/MO.
457 HRS
on Table
I - Carl
Meyer
the total
4x4 i n c h
Thickness
2.
Yield
had s u p e r i o r performance
o f t i l e / s l a b s p r o d u c e d i s 3 t o 5mm.
from t h e raw b o u l d e r s e s t i m a t e d
capital
cost
tiles:
7945 KWH
p o s s i b l e 15 c a t e g o r i e s :
1.
conveyors,
t h e i n f o r m a t i o n p r o v i d e d by
STEP 1:
As o u t l i n e d
as
p l a n t t o $742,000.
p e r month p l a n t m a n u f a c t u r i n g
162.4KW
such
a t 50 p e r c e n t .
i n 11 o u t o f a
- 28 -
3.
Production
costs
for labour,
tools
and
jade
estimated
t o be
$22.55 p e r
f 2.
t
4.
A p p r a i s a l of factory/parts support considered
5.
P l a n t area requirements
6.
Water r e q u i r e m e n t s
- 1.5 m i l l i o n
7.
Power r e q u i r e m e n t s
t o t a l a b o u t 200
8.
Number o f e m p l o y e e s r e q u i r e d i s a t l e a s t 4 t o 5.
9.
Training
10.
T e s t work
11.
B a c k i n g on t i l e s o r s l a b s n o t r e q u i r e d f o r p r o d u c t i o n .
In
the
higher
2
.
l i t r e s p e r month.
kw.
provided.
success.
remaining
capital
attributable
- 4,800 f t
superior.
to
four
cost
the
$742,000 i n c a p i t a l .
of
categories Carl
Meyer's
t h e equipment and
bandsaw
which
this
accounts
only
negative
higher
capital
f o r more
than
aspect
cost
i s the
i s mainly
one-half
of
the
- 29 -
5.5
LOFFLER - Maschinenbau oHG
This
West
polishing
Germany
company
equipment.
manufactures
However,
machine
t o chamfer,
support
i s not considered
Breton's
engineering support
Loffler's
Breton.
and
sales
Loffler's
other
the blade
as
primary
i s fixed
line
good
as
of
n o t manufacture
stone
a
cutting
tile
The e n g i n e e r i n g a n d d e s i g n
the other
t w o German
and p a r t s a v a i l a b i l i t y
technology
type
forblocking
diamond
companies
on a b r i d g e
i s probably
An
better
interesting
T h e saw b l a d e
and
although
t h e jade and c u t t i n g
saws.
i s t h e b l o c k i n g saw.
and
finishing
i s also considered superior t o L o f f l e r ,
(disc)
manufacturers
do
full
and c l e a n t h e t i l e s .
support
slabs are circular
from
for
after
groove
they
a
than
tiles
difference
and power
and t h e bed h o l d i n g t h e b l o c k
head
t o be c u t
moves b a c k a n d f o r t h .
STEP 1
The
recommended
already
mentioned
machine.
slabs
b l o c k i n g saw i s a c i r c u l a r
This
saw b l a d e
more t h a n
1/3 o f o r i g i n a l
diameter
takes
the width o f the t i l e
slightly
The
t h e 3000mm
bridge
diamond
disc
a 12mm w i d e k e r f .
t o be p r o d u c e d
4 inches thick) .
(ie:
saw, M o d e l
blade
Loffler
i s fixed
on
recommends
f o r 4x4 i n c h
Jade l o s s e s a t t h i s
TS 3000 G.
tiles
As
this
cutting
cut slabs
step are estimated at
weight.
M o d e l TS 3000G:
1.
Has a t o t a l
2.
Has f u l l
3.
Costs
installed
electronic
78 h . p .
control
$169,500.
STEP 2
A circular
blade
twice
cuts
(disc)
cutting
the t i l e
the
final
width
saw h o l d i n g a 1000mm d i a m e t e r
slabs
jade
( i e : 4 inch
thickness
b y 8mm
s l a b s f o r 4x4 t i l e s )
(2x3mm)
plus
the
thick
diamond
into
blocks
kerf
loss
LOFFLER
SYSTEM
F I G U R E
STEP
5
6
- 30 -
in
Step
in
3
(6mm).
thickness
The r e s u l t a n t
to the finished
bonded t o t h e two o p p o s i n g
finished
this
tile.
stage.
fixed
tile
loss
The recommended
f o r the slab
obtained f o r this
saw.
slab
thickness
s i d e s which
An e s t i m a t e d
carriage
12mm t h i c k
will
then
less
the f i n a l
sheet
jade
equal
thickness
e v e n t u a l l y be o n t h e b o t t o m o f t h e
o f 40 p e r c e n t
saw i s a M o d e l
and a moving
has a c r y l i c
t o saw k e r f
i s suffered at
TB 1000 B r i d g e s a w
bridge.
An a u t o m a t i c
which
has a
o p t i o n c a n be
Saw d e t a i l s a r e a s f o l l o w s :
1.
20 h . p . m o t o r
2.
Saw h o l d s a 1000 mm d i a m e t e r
3.
Price
blade
( d i s c ) a p p r o x i m a t e l y 8mm
thick.
$99,300.
STEP 3
A circular
saw,
(disc)
holding
diamond c u t t i n g
a
800mm
longitudinally.
width a r e then
The
ready
saw
s a w , M o d e l TB 8 0 0 , f u l l y
blade,
resultant
two a c r y l i c
for polishing
s m a l l e r v e r s i o n o f t h e saw u s e d
slices
backed
( S t e p 4) .
i n S t e p 2.
the
automatic,
acrylic
strips
bridge
backed
slabs
the desired
tile
T h e TB 800 saw i s e s s e n t i a l l y
a
D e t a i l s are as follows:
1.
Saw b l a d e 800mm d i a m e t e r , w i d t h a p p r o x i m a t e l y
2.
Motor
3.
Price,
6mm.
i s 25 h . p . , 1 8 . 5 kw.
including automatic bridge c o n t r o l
$80,000.
STEP 4
The a c r y l i c
backed
This
polisher
which
would
will
strips
polish
probably
a r e p o l i s h e d b y a n 8 s p i n d l e , M o d e l FS 3 0 , p o l i s h e r .
up t o 300mm w i d e
break
unbacked,
thin
polisher:
1.
Has a t o t a l
2.
Costs
installed
$125,600.
64 h . p . (44 k w ) .
slabs,
jade
relying
slabs.
on high
pressures
The M o d e l
FS
30
- 31 -
STEP 5
The
polished
30/600,
strips
are
cross-cutting
This
saw w i l l
1.
Has an i n s t a l l e d
2.
Costs
Loffler
cut slabs
the t i l e s .
between
additional
$165,000.
tiles.
(strips)
4 h.p.
with
the
desired
length
a 600mm d i a m e t e r
up t o 60mm t h i c k .
by
diamond
The M o d e l KS
a
Model
disc
KS
blade.
30/600:
(3 kw)
not manufacture a
installed
plant.
equipped
to
$23,500
does
cleaning
saw
dimensioned
Total
The
cost
machines
finishing
of this
for
An e s t i m a t e d
tool costs
machine
for bevelling, buffing
t y p e o f machine and a d d i t i o n a l equipment
moving
the
material
is
estimated
s i x p e o p l e w o u l d be r e q u i r e d
are estimated
and
at $8.50/ft
2
at
an
to operate
the
f o r production
o f 4x4
inch
- 32 -
5.6
HENSEL
Eisenwerk
and
Hensel
Bayreuth,
g r i n d i n g equipment.
hard
minerals
production
"billet"
plan,
such
system
finished,
suggested
granite
Hensel
and
and
jade.
to the current
or the i n i t i a l
7,
product.
equipment
automatic
(disc)
i n Figure
packaged
intermediate
They employ c i r c u l a r
similar
g r i n d i n g stage
illustrated
very
as
a W e s t German c o m p a n y , m a n u f a c t u r e s
takes
Their
such
would
Mohawk
slabbing
the jade
price
diamond
has
recommended
Hensel s
eight
t h e raw b o u l d e r
quotation d i d not include
as r o l l e r
conveyors
probably
require
or cranes.
more
a
than
tile
but without the
1
stage.
cutting
saws f o r c u t t i n g
procedure,
from
stone
to the
necessary
The p l a n t
the
step
i s not
four
operators
o f the appropriate
dimension,
a s minimum b y t h e m a n u f a c t u r e r .
STEP 1
The
rough
depending
Model
jade
upon
boulders
the size
55W, a n g u l a r
diameter
and one
approximately
are cut into
of tile
c u t saw.
t o be p r o d u c e d .
800mm
Water c o n s u m p t i o n a p p r o x i m a t e l y
2.
Total installed
3.
blade
power
diamond
diamond d i s c
disc.
This
with
a
1000mm i n
saw
costs
30 1. p e r m i n .
approximately
94 kw b u t v a r i a b l e
f o r h o r i z o n a l and
motors.
C a n be d e s i g n e d
this
diameter
i s accomplished
T e c h n i c a l d a t a o n t h e M o d e l 550W:
1.
vertical
This
T h i s saw h a s o n e v e r t i c a l
horizontal
$206,100.
billets
forfully
automatic
o p e r a t i o n , b u t n o t quoted
as such f o r
study.
STEP 2
An
overhead
billets
of
crane,
costing
t o an i n t e r i m
plaster,
an e s t i m a t e d
storage
several billets
on a c o n c r e t e t a b l e w h i c h
area
$5,500 o r a f o r k
where t h e b i l l e t s
beside each o t h e r .
would
lift
be f i x e d
These b i l l e t s
would go under t h e c i r c u l a r
w o u l d move t h e
i n a bed
w o u l d be m o u n t e d
saw, M o d e l 5 1 1 / I I I .
HENSEL SYSTEM
F I G U R E
7
- 33 -
STEP 3
A diamond d i s c
5mm)
from
cutting
set-up
the b i l l e t s
mitre
controls
saw, M o d e l 5 1 1 / I I I w o u l d c u t t i l e s
cemented
as w e l l
and would
t o have
as v e r t i c a l
This gantry
cuts.
I t would
t h e work
f e d through
follows:
1.
Price
2.
Saw b l a d e 400 t o 800 mm
3.
Maximum o u t p u t
on r o l l e r s .
type
saw i s c a p a b l e o f
be e q u i p p e d
require i n s t a l l a t i o n o f a concrete
as
per
together.
the desired thickness ( 3 to
with
table.
automatic
T h i s saw c a n b e
Technical specifications are
$76,600
1.2 m
2
diameter
2
p e r hour
(12.5 f t / h r . )
or approximately
2000 f t
2
month.
STEP 4
Individual
cemented
tiles
a r e removed
to plexiglass
tiles
would
(Step
6)
or acrylic
be p l a c e d
would
from
t h e saw
sheet
i n a template
produce
tiles
of
t o reach
t o ensure
the exact
recommended t h a t t h e g a p b e t w e e n s i n g l e
tiles
thickness
6.
o f t h e sawblade
at position
2
m e a s u r e a p p r o x i m a t e l y 10 t o 40 f t
a t Step
3,
their
that
(Model
final
thickness.
the last
dimension
511/III)
sawing
required.
s h o u l d be a l i t t l e
and
The
step,
It i s
l e s s than the
The s l a b s o f b a c k e d
tiles
would
crane
and a
.
STEP 5
The
sheets
o f backed
vacuum
suction
single
head g r i n d i n g
tiles
device
would
required.
This
that
2
and p o l i s h i n g
an e i g h t
would
the desired polish.
a b o u t $8.40 p e r m
t r a n s p o r t e d by
travelling
step.
A
and p o l i s h i n g machine would l a p and p o l i s h
I t i s expected
achieve
be
to the grinding
sheets.
be
would
mean
The t o o l
2
($0.80 p e r f t ) .
stage
changing
costs
Model
the m u l t i - t i l e
l a p p i n g and g r i n d i n g
t h e head
at this
8
stage
503 e ,
times
operation
by hand
to
are estimated a t
The machine c o s t i s $84,000.
- 34
-
STEP 6
The
polished
tile-slabs
would
be
t r a n s p o r t e d by
c r a n e and vacuum s u c t i o n d e v i c e t o t h e f i n a l
Model
the
541,
would
necessary
exactly
90
b r i d g e saw
Hensel
and
and
c u t s on
automatically
the
last
prices
or
T h e y e s t i m a t e d 120
finishing
and
total
last
cuts
the
and
then
or
overhead
s t a g e where a c i r c u l a r
tiles.
performed.
equipment
kw
This
the
saw
would
turntable
This
single
disc
saw
perform
would
50
1.
etc.
per
i s expected
of
five
Their
hr.
of
to require
people
would
for chamfering, cleaning
of t o t a l
a d d i t i o n a l power r e q u i r e d
tile
washing
a
degrees
cuts
d i d not quote
any
water
first
the
sawing
conveyor
turn
diamond
c o s t s $70,000.
the t i l e s .
plus
perform
roller
installed
for cranes, conveyors,
equipment
compressed
130
be
c h a m f e r i n g , g r o o v i n g and c l e a n i n g
prower
would
air.
1. p e r m i n .
required
stage.
to
require
The
for their
the f i n a l
150
1.
chamfering
of water.
operate
or grooving
machines
chamfering
per
min.
grooving
I t i s expected
the
plant
of
and
that
including
a
- 35 -
5.7
MOHAWK
The
Mohawk S y s t e m o f t i l e
manufacturing
the
lapidary
chip
and s i l i c o n
research
and development
tiles.
The t i l e s
marketing
data
collected.
and
showroom c o s t
way
reflected
industries.
project
produced
was d e v e l o p e d
from
The p l a n t
f o r t h e manufacture
were
then
An i n i t i a l
t o be
technology
was c o n s t r u c t e d
o f 4x4 i n c h
introduced
designer net sale price
production costs
considered
t o b e much h i g h e r
commercial
production
at a pilot
was e s t a b l i s h e d ,
i n no
they
CURRENT PLANT CONFIGURATION
Mohawk's
tile
manufacturing
techniques, the lapidary
sequence
were
located.
ground
our
employs
f o r grooving, chamfering
sequence
industry
performed
The b i l l e t s
having
and t h e s i l i c o n
o f the
circular
type lappers
or buffing the
c u t i n Vernon
from
known
chip industry.
jade
cutting
The s t e p s i n
locations.
rough
and t h e t i l e s
i n San J o s e , C a l i f o r n i a .
the manufacturing
from
The rough
i n V e r n o n where t h e main M i n i n g D i v i s i o n
on a custom b a s i s i n Vancouver
own p l a n t l o c a t e d
was d e v e l o p e d
i n various geographic
b o u l d e r s were c u t i n t o b i l l e t s
was
be once
and a n a l y s i s
system
were
i nthe process.
5.7.1
the
costs
would
type diamond saws, machine shop type g r i n d e r s and l a p i d a r y
i snot provision
manufacturing
These
(disc)
tiles
tile
and
These p r i c e s
research
There
The b a s i c
collection
jade
(U.S.)
market
and p o l i s h e r s .
data.
after
then
square
o f $14.50
f o r the t i l e s .
plant scale
as a
t o t h e market
( w h o l e s a l e ) o f $10.80 w e r e e s t a b l i s h e d .
the actual
used i n
steps
i n such
boulders
c u t from
were
these
jade
office
precision
billets i n
T h e r e were s e v e r a l r e a s o n s f o r
diverse
locations,
including
duty
considerations.
The
high
production costs
d e c i s i o n t o study
The
market
if
the f e a s i b i l i t y
information
manufacturing
indicated
that
month.
between
No
other
had been
gathered
sales
c o u l d be r e d u c e d .
200 a n d 250 f t
tile
sizes
this
pilot
o f manufacturing
that significant
theprice o f the t i l e s
producing
associated with
2
equipment i s p r o b a b l y capable o f a l s o
been
tiles
since
increases
plant l e dto
a t a much l o w e r
inception
the
cost.
o f the t i l e
c o u l d be a n t i c i p a t e d
The p l a n t a s s e t - u p i s c a p a b l e o f
o f 4x4 i n c h
have
scale
1/8 i n c h
produced
manufacturing
thick
jade
b y Mohawk,
t i l e s per
although the
4x8 and 6x6 i n c h
tiles.
MOHAWK
SYSTEM
M O U R E
8
- 36 -
STEP 1
The
rough
boulders
a circular
own
are cut into
48 i n c h d i a m e t e r
design.
The b l a d e
driven hydraulically.
slabs s l i g h t l y
more t h a n
4 inches
the bridge
using
a gear
The b r i d g e c a n be a d v a n c e d m a n u a l l y
However,
limited
t o a c u t t i n g depth
using
d i a m o n d s e g m e n t e d h y d r a u l i c b r i d g e saw o f Mohawk's
moves a l o n g
slab.
thick
the jade
boulder
often
must
be
moved
advance
f o r each
because
mechanism
successive
t h e saw i s
o f a b o u t 21 i n c h e s .
STEP 2
The
48 i n c h d i a m e t e r
slabs
into
billets
approximately
sufficient
and
70
slightly
linear
t o produce
consumables
saw u s e d
per f t
2
greater
feet
about
f o r Step
than c r a t e d and s h i p p e d
i n Step
of
225 f t
1 i s used
than
billets
2
4
again
inches
2 t o c u t the
square.
a r e produced
o f 4x4 t i l e s .
1 and 2 i s about
i n Step
A
total
of
This
is
monthly.
The c o s t o f t o o l s ,
$12.70 p e r f t
2
.
labour
The b i l l e t s a r e
t o the custom g r i n d i n g p l a n t a t a t o t a l
c o s t o f $0.90
.
STEP 3
The
rough
vertical
machine
billets
are precision
spindle grinder
i s used
ground
to exactly
for this
4x4 i n c h e s
process.
Mohawk
i n 1 9 8 5 a t a c o s t o f $60,000 b u t i t h a s n e v e r
grind b i l l e t s .
h . p . (55 kw) , r e q u i r e s 100 l i t r e s / m i n .
of
g r i n d i n g enough b i l l e t s
t o supply
square.
purchased
been s e t - u p
T h i s u s e d g r i n d e r i s a , MAS M o d e l BRV 7 0 .
40
and
1000 f t
month.
The c o s t o f c u s t o m g r i n d i n g t h e b i l l e t s
tiles.
F r e i g h t and duty on t h e b i l l e t s
2
I t h a s an i n s t a l l e d
o f 4x4 i n c h
i s $18.27 p e r f t
t o San Jose
a
o r used t o
o f c o o l a n t and i s p r o b a b l y
at least
such
A
2
capable
t i l e s per
o f 4x4 i n c h
t o t a l s $7.56 p e r f t 2
#
- 37 -
STEP 4
The
slicing
diamond
to
machine,
d i s c blade
18" diameter
a
cuts
DO
tiles
blades
high
billet
kerf
losses
1/D M i c r o
from t h e b i l l e t s .
Slicer,
This
of cutting
equipped
machine w i l l
with
a
h a n d l e 14"
a maximum o f 225 f t
2
per
T h i s machine does n o t c u t a s a c c u r a t e l y a s d e s i r e d ,
(approximately
and r e q u i r e s an o p e r a t o r
the C a l i f o r n i a p l a n t .
70
and i s c a p a b l e
month o f 4x4 i n c h t i l e s .
has
ALL, Model
4mm
per cut) w i l l
almost f u l l
The b i l l e t s
time.
This
c u t a maximum 4
machine
a r e g l u e d on p l a t e s p r i o r
inch
was s e t - u p i n
to cutting.
STEP 5
The
tiles
are placed
on
lapper which i scapable
minutes.
This
an o p e r a t o r ,
one h a l f
time.
table,
a
Speedfam
o f l a p p i n g 48 - 4 x 4 i n c h t i l e s
i s 2,750
requires
the lapping
when
f t
2
p e r month
operating
actual
a t 2,000
Model
a t one time
production.
tiles
SNF 48
p e r month,
BTAW,
i n a b o u t 10
This
machine
approximately
STEP 6
The
lapped
tiles
are carried
to the polishing
SNG 32 SPAW, p o l i s h e r s p o l i s h
the t i l e s
will
and i s capable
ft
2
hold
12 - 4x4 i n c h
p e r month,
person operates
a
tiles
combined
2,000
two p o l i s h e r s p l u s
f t
2
s e c t i o n where
to a mirror
finish.
of polishing
p e r month
inspects t i l e s
2, S p e e d f a m
Each p o l i s h e r
approximately
of actual
Model
1,000
production.
a t 2,000 t i l e s
One
2
(225 f t ) p e r
month p r o d u c t i o n .
STEP 7
The
polished
tiles
a r e removed
from the p o l i s h e r , sorted
and p a c k a g e d f o r s t o r a g e o r s h i p m e n t .
cleaned,
inspected
- 38 -
The t o t a l
4
c o s t breakdown i s i l l u s t r a t e d
t h r o u g h 7,
increment
2
ft ,
i s $33.00
which
compared
i s $47.75
per
operating,
f o r l a b o u r , maintenance
f t
2
i s the comparable
i n the report,
not
.
Labour,
figure
tools
and
The
total
and t o o l s p e r f t
and
to the other
i n c l u d i n g t h e Table
i n c l u d i n g overhead
The Mohawk p l a n t e m p l o y s
i n Table I I .
I
jade
comparison.
total
2
.
of
The
total
manufactures
administration
a t o t a l of f i v e people.
costs
cost
Steps
labour
97.68
per
described
and
Actual
$115.71
costs
per f t
of
2
.
TABLE I I
MOHAWK PLANT COSTS
IMPROVED
COST
PER F T
($)
($)
2
ITEM
1.
CURRENT
COST
PER F T
Labour f o r b l o c k i n g
(cutting billets)
7.90
2
7.90
( S t e p s 1 t o 2)
2.
Labour f o r c u t t i n g and p o l i s h i n g
33.00
17.50
3.85
( S t e p s 4 t o 7)
3.
T o o l s and consumables
( S t e p s 1 t o 2)
4.80
4.
T o o l s and consumables
( S t e p s 4 t o 7)
14.25
11.40
5.
Grinding
billets
18.27
6.05
6.
F r e i g h t and duty
8.46
2.75
7.
Cost o f Jade @ $1.50/lb.
11.00
8.50
SUB-TOTAL
8.
(labour,
- Vancouver
t o o l s , jade)
Miscellaneous Costs
97.68
18.03
57.95
7.85
(rent, depreciation, u t i l i t i e s )
TOTAL OPERATING COSTS
(exclusive of administration
$115.71
& overhead)
$65.80
-
5.7.2
MOHAWK PLANT IMPROVEMENTS
Mohawk's
current
manufacture
overhead
and
1.
4x4
and
inch
be
plant
jade
about
charge
$140.00
of
per
the
2
percent,
.
labour
in
take advantage of
order
to
costs
rate
or
from
rent,
II) .
the
Several
maintaining
of
(Table
be m o d i f i e d
production
approximately
exclusive
20
f t
-
total
charges
i d e n t i f i e d which could
Increase
costs
tiles
administrative
administrative
probably
can
pilot
39
per
depreciation,
Assuming
actual
areas
$98.00
a modest
overhead
costs
manufacturing
to reduce the manufacturing
the
allowing
current
225
incrementally
economy o f
scale
and
f t
2
small
per
to
utilities
manufacturing
i n the
2
f t
process
costs:
month
labour
maintaining
are
while
increases
fixed
cost
levels.
2.
R e d u c e f r e i g h t and
3.
Improve r e c o v e r y
4.
Reduce or
Some o f
1.
the
(yield) of
eliminate grinding costs
five
would
would
additional
involve
increase
month.
saws
at
for
billets.
The
Improved
total
cost
sawing
jade y i e l d
t o an
involve:
machines
estimated
large
cost
at
a
three
the
be
cost
of
about
additional
$105,000.
employees,
p r o c e s s t o a b o u t 1,125
automated
would
billets.
boulders.
at Step 4 of
one,
saw
would
similar
but
probably
only
f t
be
one
but
2
per
more
additional
required.
production
a
an
production
e m p l o y e e w o u l d be
Increased
slicing
hiring
Purchasing
appropriate.
2.
jade from
economies o u t l i n e d above would
Purchase
This
duty charges for t r a n s p o r t i n g
of
would
about
also
require
$100,000
and
purchasing
require
techniques would reduce b i l l e t
estimated
35%.
three
three
grinding
more
more
costs
blocking
employees.
and
improve
- 40
3.
One
a d d i t i o n a l large p o l i s h e r capable
production
than
4x4
at Step 6 to a t t a i n
inch.
The
e m p l o y e e s w o u l d be
4.
-
The
vertical
to
dimension.
ground
to
cost
r e q u i r e d a t S t e p s 5,
6 and
would
linear
of
foot
surface
required
280
1,000
cost
grinder
f t
an
billet).
of
One
would
month o f
tiles
two
allow
larger
additional
7.
grind
feet
of
the
billets
billets
finished
estimated
per
tiles
i s $40,000;
could
linear
2
2
f t
capital
produce
consumables
p o l i s h i n g 8x8
a b o u t 1,250
estimated
spindle
A
of
would
tile.
$1.50
per
employee would
f t
be
square
have
Tools,
2
of
tile
required
and
to
be
power
and
($5.36
per
to operate
this
machine.
5.
Buying
consumables
t o o l s and
6.
Duty
into
value
in
bulk
i s expected
to
result
in a
20%
reduction
in
consumables c o s t s .
the
United
(manufacturing
States
should
costs).
This
be
not
more
than
d u t y r e d u c t i o n may
5%
of
the
declared
require Federal
and
P r o v i n c i a l Government a s s i s t a n c e .
A
detailed
illustrated
be
a
40
percent
plant
the
of
comparison
i n Table II.
percent
in
However,
l e s s than
would
target
have
the
i n labour,
costs
these
i f
current
i n the
criteria.
f t
t o o l s and
rent,
reduced
$100.00 p e r
t o be
pricing
of
and
improved
I f a l l improvements c o u l d
reduction
reduction
included.
price
cost
costs
2
.
The
$35.00 t o
be
jade
do
labour,
$40.00 p e r
implemented
production
depreciation
still
Mohawk
and
not
meet
t o o l s and
f t
2
System
there
would
c o s t s and
utility
the
jade
range or
a
costs
target
costs
is
43
are
retail
for
a
l e s s t o meet
-
6.
PREFERRED MANUFACTURING SYSTEM
In order
tool
per
f o r a system t o q u a l i f y as a candidate
and jade
f t
this
2
costs
basis,
criteria.
equipment
primarily
as being
A l l
most
on Table
including
categories.
manufacturer
other
Meyer
costs
and comparing
that
rated
very
well
there
1.
by t h e lower o p e r a t i n g
costs
forecast
for
a r e s e v e r a l u n i q u e b e n e f i t s t o be d e r i v e d
The bandsaw
large slabs
Model
463K
will
cut thin
slabs
(3-5mm
well
i n another
This
best or
the capital
i n four
thick)
cost
years or
Moreover
plant:
and produce
(2200mmxl600mm).
3.
The bandsaw i s q u i e t ,
requires
comparable systems, uses about
about one-half
5.
performance
t h e C a r l Meyer
Bandsaw k e r f l o s s i s a p p r o x i m a t e l y 1/2 a n y c o m p a r a b l e
any comparable
T h e bandsaw i s a l s o
cut
were
the various
t h e C a r l Meyer p l a n t .
from
cost
costs
and second
However,
2.
4.
the
was H e n s e l .
category
categories.
this
i n six of the fifteen
d i f f e r e n t i a l between C a r l Meyer and H e n s e l w o u l d be e q u a l i z e d
less
meet
production
and performed
i n t h e equipment c o s t
other
with
and t h e manufacturers'
manufacturer
i n five
associated
best
t o $40.00
do n o t q u a l i f y on
manufacturers
performed
o f production
best
Systems
including
criteria
the labour,
m u s t be $35.00
Mohawk
i n assessing
C a r l Meyer
The o t h e r
tiles
equipment
important
I.
for consideration,
labour
criteria
These
cost
was r a t e d
to Carl
or modified
separate
manufacturers.
categories
o f 4x4 i n c h
due t o t h e h i g h
process.
summarized
equal
The c u r r e n t
Fifteen
identified
five
o f production
or less.
manufacturing
are
41 -
30 p e r c e n t
10 p e r c e n t
l e s s water,
t h e power o f some
and has t o o l
jade
for
sale
as bulk
since
i t can
down t o a b o u t 4mm.
d o e s n o t d e f l e c t when s t a r t i n g a c u t ,
diamond segments m i s s i n g
costs
system.
ideal for blocking
s l a b s o f any t h i c k n e s s
The bandsaw b l a d e
approximately
system.
and does n o t r e q u i r e c o n t i n u a l
can operate
tensioning.
with
- 42
6.
Acrylic
tiles
or
or
similar
slabs,
type
of
although
-
backing
for
is
not
required
some
applications
the
p l a n t i s low
for
production
of
probably
be
i t would
appropriate.
7.
The
total
This
which
8.
Total
will
power
requirement
reflect
i s a f i x e d charge
water
(Hensel) .
This
will
Carl
Meyer's
s u p e r i o r and
be
the
are
cost of
about
reflected
r e c l a m a t i o n and
engineering
after
on
energy
(an e s t i m a t e d
and
the
200
demand
kw) .
charge,
d e p e n d e n t upon i n s t a l l e d , o p e r a t i n g h o r s e p o w e r .
requirements
i n e x p e n s i v e water
9.
directly
for
i n lower
filtration
design
s a l e s support
one-half
and
water
the
closest
charges
and
competitor
the
most
system.
factory
i s a l s o expected
support
t o be
is
considered
excellent.
- 43 -
6.1
As
D E T A I L E D COST A N A L Y S I S - CARL MEYER
outlined
$742,000.
of
the
i n Table
I
However, t h e r e
equipment
considered
the basic
are other
manufacturer
i n the cost
plant
cost
i s estimated
but w i l l
Therefore,
be r e a l
these
costs
cost
incurred
were
C A P I T A L COSTS
Equipment f o r t i l e
Installation,
Freight,
airfare,
taxes
Miscellaneous
Building
manufacture
training
$
- C a r l Meyer
other
88,000
equipment
100,000
renovation
50,000
Contingencies
150,000
TOTAL
2.
$ 1,151,000
OPERATING COSTS
(4x4 i n c h t i l e p r o d u c t i o n 8 1000 ft
z
per mo.)
Tools
Jade
6.08
(@ $1.50 / l b . )
5.95
Labour
10.52
E l e c t r i c power
Water r e c l a m a t i o n
Rent
1.70
& consumption
.50
2
($5/ft /yr)
2.00
Miscellaneous
Amortization
TOTAL
742,000
21,000
etc.
2.50
and d e p r e c i a t i o n @ 10%/yr.
9.59
$
not
never-the-
less.
1.
at
c o s t s w h i c h w o u l d be i n c u r r e d i r r e s p e c t i v e
chosen.
comparison
equipment
38.84
- 44 -
The
1.
e c o n o m i c s o f t h e p r o j e c t a r e e n h a n c e d when o n e c o n s i d e r s
4x4
inch
associated
tiles
have
the
tool
costs.
lowest
Other
production
size
tiles
rates
should
be
that:
and
less
the
highest
expensive
to
produce.
2.
The p l a n t
i s capable
of producing
This production rate w i l l
3.
Revenues
will
manufacturing
4.
Other
jade
be
result
realized
from
1,720
i n lower
bulk
jade
f t
2
o f 4x4 i n c h t i l e s
monthly.
unit costs.
liberated
as p a r t o f the
tile
process.
products
are
equipment r e q u i r e d f o r t i l e
likely
to
manufacture.
be
manufactured
using
the
same
-
7.
45
-
PLANT S I T E S E L E C T I O N
Selection
of
a
the
of
several
basis
1.
site
the
proposed
o p e r a t i n g and
Marketing
considerations
access
domestic
plant
2.
for
to
and
and
tile
manufacturing plant
economic f a c t o r s
for
tiles,
p r o d u c t s to customers are
Transportation
costs
p r o d u c t s to the
of
raw
and
bulk
markets.
considered
materials
made
on
including:
slabs
international
i s t o be
jade
including
Convenience
of
the
important.
from the
minesite
and
finished
customers.
3.
Suitable
land
and
4.
Utility
availabilities
garbage d i s p o s a l ,
building
costs
and
and
availabilities.
costs
including
effluent disposal,
5.
Government a s s i s t a n c e
6.
Taxation rates
7.
Operating
considerations
water,
sewer,
etc.
programs a v a i l a b l e
in alternative
power,
in alternative
locations.
locations.
including
weather
conditions
in
alternative
locations.
8.
Based
the
Availability
upon
plant
minesite
Terrace
the
above
location;
having
stood
a
out
s k i l l e d or
criteria
a
as
Langley
or
interior
cities
such
conditions.
two
northern
relatively
Surrey,
weather
of
the
as
are
Prince
labour
force.
areas
of
the
Province
location
on
the
transportation
moderate
best
Delta
technical
climate
candidate
for
probable
George
and
the
Lower
n o r t h and
southern
were
a
were
B.C.
eliminated
considered
for
route
the
Mainland
the
to
location.
municipality
locations.
due
from
severe
of
Central
winter
- 46 -
7.1
TERRACE
Communities
i n North
Development C o u n c i l
Central
British
Columbia
have
organized
the Northern
o p e r a t e d by P a c i f i c C o n g r e s s P r o j e c t s C o r p . l o c a t e d a t :
638-999 Canada
Place
VANCOUVER, B.C. V6C 3E1
ATTENTION:
Information
J i m Davidson
PHONE:
(604) 6 8 3 - 0 4 0 1
TELEX:
04-54244
was
received
T e r r a c e and K i t i m a t .
from
the Northern
For information
Development C o u n c i l ,
on K i t i m a t
the contact i s :
B r i a n Mayhew
Director o f Planning,
District
270 C i t y C e n t r e
K I T I M A T , B.C. V8C 2H7
PHONE:
(604) 6 3 2 - 2 1 6 1
TELEX:
047-84515
Terrace contact i s :
Robert Greno, C i t y D i r e c t o r
The C i t y o f T e r r a c e
3215 E b y S t r e e t ,
TERRACE, B.C.
PHONE:
V8G 2X8
(605) 635-6311
1-800-772-9886
of Kitimat
the C i t y of
- 47 -
Information
on T e r r a c e ,
Kitimat
sources.
Information
on
acquired
from
Expansion
and
information
incentive
these
Federal,
sources
the M i n i s t r y
was
Federal
unemployment.
will
of
available
and
and S m a l l
a l l t h e above
Municipal
grants
Provincial
i s currently
grants
No
employment
and
under review
are
available
Engineering
estimates
up-to-date
training
by t h e P r o v i n c i a l
f o r areas
of
a t the Municipal
a n d some
were
Industrial
Business.
programs a l s o a r e a v a i l a b l e
Civil
from
t h e Department o f R e g i o n a l
Industry
employment
Assistance
provide
plus
area
was g a t h e r e d
Provincial
regarding
programs as t h i s
Government.
Terrace
same
and v i c i n i t y
capital
high
level.
works f o r
the p l a n t i f i t i s l o c a t e d i n Terrace.
Pertinent
details
regarding
l o c a t i o n o f Terrace
1.
2.
-
Partnership
3.
commercial
type
below.
property
n e t f o r $3.00 t o $6.00 p e r f t
Industrial
tax
are l i s t e d
Figure
1
shows
the
and i n f o r m a t i o n on c l i m a t i c c o n d i t i o n s .
Warehouse
absolute
Terrace
taxes
i s i n surplus
2
and l e a s e s
per year.
a r e a b o u t $46 p e r $1,000 o f n e t t a x a b l e v a l u e .
i n E n t e r p r i s e Program w i l l
at
privde
a 52 p e r c e n t
The
property
reduction.
Industrial/Commercial
property
sells
f o r $15,000
to
$30,000
per
acre.
4.
W a t e r r a t e s a r e $.171 p e r c u b i c m e t r e p e r m o n t h .
5.
Sewer r a t e s a r e $.142 p e r c u b i c m e t r e p e r m o n t h .
6.
G a r b a g e r a t e s a r e $28.60 p e r 3 y a r d c o n t a i n e r p e r m o n t h .
7.
Transportation
Edmonton
Rupert
links
to Prince
and P r i n c e
include;
Rupert
George
C.N.R. T e r r a c e
mainline;
and Highway
Highway
37
K i t i m a t b r a n c h l i n e and
16
connecting
Prince
to Kitimat, a distance
of
- 48 -
57
kilometers;
flight
and
airport
d a i l y connecting
Prince
Electricity
Province
with
two C P .
t o Vancouver;
flights
daily
and one
P.W.
access to the Ports o f Kitimat
Rupert.
rates
are
and a r e d e t a i l e d
the
same
i n the
i n Appendix IV.
north
and
south
of the
- 49
7.2
SURREY
Surrey
and
offer
other
similar
participant
those
-
municipalities in
business
in Partnership
2.
Industrial
3.
Land
4.
per
2
are
per
5.
Sewer r a t e s a r e
6.
Commercial
the
7.
$25
Terrace,
more
Langley
Surrey
offers similar
tax
also
a
incentives
to
industrial
land
than
any
per
f t
$1,000 o f n e t
taxable
B.C.
property
value.
ranges
between
depending
consumption
upon
increases.
quantity
The
used,
basic
rate
with
the
i s $20.83
quarter.
essentially
per
rates
the
vary
same a s
Terrace.
to
extent
some
month r a n g e f o r a 3 y a r d
but
are
generally
Within
k i l o m e t e r s of Vancouver I n t e r n a t i o n a l A i r p o r t .
(b)
S e r v e d by H i g h w a y s - 1,
(c)
Railway
include:
(d)
Port
l i n e s o f B.C.
the
in
container.
(a)
adjacent
per
sizes.
links
on
2
other
Transportation
29
Delta
acre.
graduated,
garbage
t o $30
is
f o r $4.00 t o $6.00 p e r
industrial/commercial
as
and
a r e as f o l l o w s :
leases
a v e r a g e a b o u t $31
for
decreasing
f t
has
$160,000 p e r
rates
100
property
as
i n c l u d i n g 8 i n d u s t r i a l parks of various
prices
Water
rate
also
taxes
$ 6 0 , 0 0 0 and
Like
D e t a i l s on S u r r e y
Surrey
municipality
such
i n E n t e r p r i s e and
Commercial/industrial
year.
vicinity
opportunities.
o f f e r e d by T e r r a c e .
1.
the
Fraser
1A,
10,
15,
99,
99A,
91.
H y d r o , B.N.R., C.N.R. and
River
serving
t o t h e P o r t o f V a n c o u v e r and
deep
New
C.P.R.
water
shipping,
Westminster.
and
- 50 -
8.
Electricity
Province
rates
are
and a r e d e t a i l e d
the
same
i n the
i n Appendix IV.
north
and
south
of
the
- 51 -
7.3
CONCLUSIONS AND RECOMMENDATIONS
Until
such
purchase
land
time
as an a c t u a l
and b u i l d
plant
site
o r l e a s e and renovate
and b u i l d i n g s
are illustrated
lower
i n Surrey.
i n Table
IV.
lower
l e a s e c o s t s m a r g i n a l l y lower
i nTerrace.
value, but land values
in
Surrey.
sales,
jade
location
location,
jade
office
for a
i nTerrace
and jade
site
products
will
Mainland.
will
Plant, marketing
be c o m b i n e d f o r a L o w e r M a i n l a n d
construction
i nSurrey
i n an o v e r a l l
be l e s s
higher
require a
Therefore,
expensive
t h e economy o f a n o r t h e r n p l a n t l o c a t i o n w i l l
two b u s i n e s s p l a c e s .
to
may b e m a r g i n a l l y
Taxes a r e 25% lower
i n t h e Lower
plant
building
t h a n o n t h e Lower M a i n l a n d ,
arehigher, resulting
bulk
administrative
Terrace
for
tiles,
Estimated
Construction costs
Land c o s t s a r e s u b s t a n t i a l l y
on
and t h e d e c i s i o n
i s made, t h e a c t u a l c o s t s r e l a t e d t o
c a n n o t be f i n a l i z e d .
costs
Marketing
i s selected,
and a d m i n i s t r a t i v e
based
tax cost
showroom,
although
than
be reduced
with
a
a
Surrey
by t h e need
facilities
would
location.
Other c o s t s f o r c o n s i d e r a t i o n i n c l u d e :
o
38 p e r c e n t l o w e r w a t e r r a t e s i n S u r r e y .
o
Lower
marketing
Mainland
o
costs
related
t o showing
clients
bulk
jade
a t a Lower
location.
Increased
costs
related
to separating
the manufacturing
and marketing
such a s a d m i n i s t r a t i o n ,
o
P r o x i m i t y t o t h e U.S.A. m a r k e t .
A Surrey
location
actually
borders on
t h e U.S.A.
o
The c o s t
cheaper
finished
Terrace.
of transportation
t o Terrace
products
than
i s only
o f raw jade
t o Surrey
i sapproximately
and t h e s a v i n g s
marginally
cheaper
from
$.15 p e r p o u n d
on
Surrey
transporting
than
from
TABLE IV
BUILDING CONSTRUCTION COST ESTIMATE
PROPOSED JADE T I L E PLANT/WAREHOUSE/OFFICE
Vancouver, B.C. (Area)
($)
Warehouse s t r u c t u r e (metal s u p e r s t r u c t u r e , t i n r o o f )
A p p r o x . 40 x 120 w i t h 16-0 c e i l i n g , s l a b f l o o r ,
& i n d u s t r i a l overhead doors
86,400.00
Service
15,000.00
to structure
(allowance)
Mechanical
(plumbing, h e a t i n g , water, sewer, gas, e t c . )
30,000.00
Electrical
(service entrance,
power, l i g h t i n g , e t c . )
25,000.00
& Paving/Gravelling
40,000.00
Earthworks, S i t e preparation,
O f f i c e S t r u c t u r e & p a r t i t i o n i n g i n c l u d i n g washrooms a n d
l u n c h r o o m . A p p r o x . 40 x 60 f r a m e p r e f a b r i c a t e d w i t h
8-0 c e i l i n g
and r e q u i r e d d o o r s & windows
86,400.00
Mechanical
20,000.00
Electrical
15,000.00
L o a d i n g Dock a n d Ramp f o r V e h i c l e s
15,000.00
Chain Link Fencing
( a p p r o x . 800 l i n .
ft.)
8,500.00
Access/Egress driveways and curb c u t s
5,000.00
Development Charges
(Municipal)
5,000.00
Consultants,
specifications, etc.
8,000.00
Contract
TOTAL
plans,
Management,
supervision, etc.
12,000.00
$ 371,300.00
- 52 -
In
conclusion:
Capital costs
Operating
including land
costs
TERRACE
i n c l u d i n g water and
weather c o n s i d e r a t i o n s
Marketing
LOWER MAINLAND
considerations
convenience f o r viewing
including
t h e process and
p r o d u c t s and p r o v i d i n g customer s e r v i c e s .
IT
IS
SURREY,
RECOMMENDED
WOULD BE
BUSINESS VENTURE.
THAT
A
LOWER
MAINLAND
MOST ADVANTAGEOUS
FOR
LOWER MAINLAND
PLANT
THE
LOCATION,
ONGOING
SUCCESS
SUCH
OF
AS
THE
- 52 -
8.
BIBLIOGRAPHY
B e l y k , 3.E., W a t t o , B., H u t c h i n s o n , B., L i m , B.C. 1 9 7 3 ,
The m e c h a n i c a l p r o p e r t i e s o f B.C. J a d e ; u n p u b l . r e p . , D e p t .
E n g . , U.B.C.
of
Geol.
B.C. C e n t r a l C r e d i t U n i o n 1 9 8 5 , K i t i m a t - S t i k i n e R e g i o n a l P r o f i l e ,
R e p o r t p r e p a r e d b y E c o n o m i c s D e p t . , B.C. C e n t r a l C r e d i t U n i o n , V a n c o u v e r ,
B.C.
CTI - C o n s t r u c t i o n T e s t i n g 1984, R e p o r t on T e s t i n g o f J a d e T i l e Samples,
U n p u b l i s h e d r e p o r t , p r e p a r e d f o r Mohawk O i l C o . L t d . b y C T I
C o n s t r u c t i o n T e s t i n g a n d I n s p e c t i o n , P o r t C o q u i t l a m , B.C.
E r t i n g s h a u s e n , W., 1 9 8 6 , Wear P r o c e s s e s i n S a w i n g H a r d S t o n e ;
D i m e n s i o n a l S t o n e , J a n / F e b 1986
G o v e r n m e n t o f C a n a d a 1 9 8 6 , DRIE I n B r i t i s h C o l u m b i a ,
Report p r e p a r e d by Dept. o f R e g i o n a l I n d u s t r i a l E x p a n s i o n
Government o f Canada, 1985, I n d u s t r i a l and R e g i o n a l Development Program,
M i n i s t e r o f S u p p l y a n d S e r v i c e s C a n a d a , C a t . No. C 2 - 8 3 / 1 9 8 5
ISBN 0-662-54128-6
G r e n o , R.S., 1 9 8 6 , T e r r a c e . . . . A s A M a t t e r o f F a c t ,
p u b l i s h e d by t h e T e r r a c e P l a n n i n g and Economic Development
Homenuke, A.M., 1 9 7 6 - 1 9 7 9 ,
unpublished
reports
Exploration Ltd.
Department
C r y Lake Jade Mines O p e r a t i o n s Annual R e p o r t s ,
prepared
f o r Mohawk
O i l Co. L t d . by
Tricon
Learning, S.F., 1 9 7 8 , J a d e I n Canada,
G e o l o g i c a l S u r v e y o f Canada Paper 78-19
Mohawk O i l C o . L t d . , 1 9 7 6 - 1 9 8 5 , V a r i o u s u n p u b l i s h e d memos
r e g a r d i n g Jade T i l e M a n u f a c t u r i n g and M a r k e t i n g
P r o v i n c e o f B.C., 1 9 8 4 , D o i n g B u s i n e s s i n B r i t i s h C o l u m b i a ,
Queens P r i n t e r
f o r B.C. 2 5 0 0 / 5 / 8 4 ,
Ministry
of Industry
Business
and
Small
R e g i o n a l D i s t r i c t o f K i t i m a t - S t i k i n e , 1984, Economic Development O p p o r t u n i t i e s
for
S m a l l and Medium-Sized Resource Development
i n Northwest
British
Columbia
W a l d n e r , M.W., 1 9 8 5 , K u t c h o C r e e k - K i n g M o u n t a i n O p e r a t i o n s 1 9 8 1 - 1 9 8 4 ,
u n p u b l i s h e d r e p o r t p r e p a r e d f o r Mohawk O i l C o . L t d .
Y o r k e - H a r d y , R.W., W e y g a n d t , T., 1 9 8 4 , C r y L a k e J a d e M i n e s O p e r a t i o n s , 1 9 8 0 ,
u n p u b l i s h e d r e p o r t p r e p a r e d f o r Mohawk O i l C o . L t d .
APPENDIX I
EQUIPMENT MANUFACTURERS - CUTTING & GRINDING TECHNOLOGY
PEDRINI s.p.a.
V i a F u s i n e , 1 - 24060 C a r o b b i o d e g l i A n g e l i
ITALY
PHONE:
TELEX:
035/951043
302182 PEDRIN 1
S a l e s Manager:
Sergio
Berti
* **
GREGORI s.p.a.
6015 S c h i o ( V I ) - I t a l i a
P.O. B o x N. 129
PHONE:
TELEX:
(0445) 2 3 2 3 1
4 8 0 4 7 3 GREG-1
S a l e s Manager:
Nico
Cazzola
* **
ADMAC
21246 - 6 8 t h A v e n u e S o u t h
KENT, W a s h i n g t o n 9 8 0 3 2 , USA.
PHONE:
(206) 8 7 2 - 7 1 5 3
Rod D r a u g h t o n
Jim White
* **
CUT-A-DIE CANADA LTD.
7447 V i c t o r i a P a r k A v e n u e
MARKHAM, O n t a r i o
L3R 2Y7 CANADA
PHONE:
Manager:
( 4 1 6 ) 475-0324
(416)
499-7333
J i m McMicking
(Bergamo)
BRETON s.p.a.
31030 C a s t e l l o D i G o d e g o (TV)
ITALY
PHONE:
TELEX:
(0423) 4 6 8 1 4 1
410539 - 431445 BRETON 1
BRETON OF THE AMERICAS, INC.
3221 N.W. 1 0 t h T e r r a c e
S u i t e 506
FT. LAUDERDALE, F l o r i d a
33309 USA
PHONE:
TELEX:
(305) 564-2708
821915
Secretary:
President:
Joseph Wetzel
R o g e r N. B a k e r
* **
LOFFLER Maschinenbau oHG
8831 L a n g e n a l t h e i m 1 B a y
WEST GERMANY
PHONE:
TELEX:
(09145) 4 6 1
624606
Owner:
Mr. L o f f l e r
GRANQOARTZ TRADING INC. - U.S.A. R e p r e s e n t a t i v e f o r L o f f l e r
788 S c o t t d a l e Road
P.O. B o x 33569
DECATUR, G e o r g i a
30033-0569
PHONE:
(404) 2 9 2 - 0 1 3 5
P e t e r Edwards
* **
EISENWERK HENSEL BAYRETJTH/Dipl-Ing. B u r k h a r d t GmbH
P o s t f a c h 5020
D-8580, Bayreuth 13,
WEST GERMANY
PHONE:
TELEX:
(0921) 508-0
642823 ebubt
Marketing D i r e c t o r : Wolfgang Behr/Franz Kostner - Dipl-ING
S a l e s Manager: N o r b e r t Sieder
* **
CARL MEYER
P o s t f a c h 380
D-8590 M a r k t r e d w i t z
WEST GERMANY
PHONE:
TELEX:
(09231) 4133
641274
G. K e i c h e l
A.K. Backraund
* **
ARVAN
1995 Boundary Road
VANCOUVER, B.C.
PHONE:
(604) 299-6100
P l a n t Manager:
Bob Armstrong
APPENDIX I I
JADE T I L E FEASIBILITY STUDY PLAN
JADE T I L E
FEASIBILITY STUDY
PLAN
MARCH 1986
PREPARED BY:
M. WALDNER
J . SMITH
TABLE OF CONTENTS
PAGE
1.
2.
INTRODUCTION
1.1
History
1.2
Philosophy
1-2
and Purpose o f Study
PROPOSED FEASIBILITY STUDY - INVESTIGATION OF T I L E
2-3
3-4
MANUFACTURING
2.1
Current Plant Configuration
4
2.2
Current Plant Modification
4
2.3
Alternate Processes
5
2.4
Report Preparation
6
3.
FEASIBILITY STUDY SCHEDULE AND PERSONNEL
7-8
4.
BUDGET
8-9
APPENDIXES
APPENDIX I
F E A S I B I L I T Y STUDY SCHEDULE
APPENDIX I I
SCHEDULED PERSONNEL & A C T I V I T I E S & BUDGET
INTRODUCTION
1.1
HISTORY
C r y L a k e J a d e M i n e s L t d . , a w h o l l y owned s u b s i d i a r y o f Mohawk O i l
Co. L t d . , f i r s t
as
a primary
began t h e i n - s i t u
product
mining
i n 1976 n e a r
of Nephrite
Dease Lake
(B.C.)
i nNorthern
Jade
British
Columbia.
During
t h e 10 y e a r
shipped
from
p e r i o d a p p r o x i m a t e l y 830 t o n s o f j a d e h a s b e e n
the minesite
v i a"cat-train"
Lake and thence
b y t r u c k t o S o u t h e r n B.C.
In
began
1 9 8 2 Mohawk
method o f u s i n g
60%
t h e lower
quality
jade
tile
jade which
manufacturing
accounted
o f p r o d u c t i o n o r 75% t o 95% o f r e s e r v e s .
assist
i nliberating
Beginning
involved
rough
by
investigating
and by a i r t o Dease
would
and r e c o v e r i n g t h e higher q u a l i t y
jade.
transporting
billets
tiles
jade
were c u t .
manufactured.
t h e mine
These b i l l e t s
site
The
process
t o Vernon
were t h e n p r e c i s i o n
These p r e c i s i o n
also
billets
where
ground
were
then
l a p p e d a n d p o l i s h e d i n Mohawk's p l a n t i n C a l i f o r n i a .
A marketing
tile
were
from
a c o n t r a c t o r i n Vancouver.
cut,
f o r about
This
i n 1983 j a d e
as a
c a m p a i g n was o r g a n i z e d
manufacturing
was i n i t i a t e d .
a t about
t h e same
time
that
- 2 -
Expenditures
related
to tile
manufacturing
t o t a l e d a p p r o x i m a t e l y $1,449,700 s i n c e 1983.
This
has
includes:
(i)
M a n u f a c t u r i n g E q u i p m e n t i n t h e U.S.
$ 74,500.00
(ii)
M a n u f a c t u r i n g Equipment i n Canada
$ 93,500.00
( i i i ) M a r k e t i n g expenses
(Advertising primarily)
(iv)
Manufacturing
(v)
M a n u f a c t u r i n g expenses and r e l a t e d
Revenues s i n c e
such
as
quality
legs
jade
a n d book
$370,900.00
tile
sales
ends
costs
approximately
$10.00 p e r t i l e
retail
although
f o r 1/8" t h i c k
and other
which
j a d e t o t a l a p p r o x i m a t e l y $170,000
Manufacturing
tiles
$379,100.00
i n Canada
1983 f r o m
table
$531,700.00
e x p e n s e s i n t h e U.S.
Administration
jade
a r e made
(Canadian
4"x4" square
products
from
normal
mark-ups
tiles
o r $90.00 p e r s q u a r e
should
have
these
tiles
lower
Funds).
have
foot.
been
These
f o r a b o u t $ 1 7 . 5 0 , o r a b o u t $150.00 p e r s q u a r e
more t h a n $ 1 7 5 . 0 0 p e r s q u a r e
1.2
and marketing
foot,
retailing
at
foot.
PHILOSOPHY AND PURPOSE OF STUDY
The
general
the
viability
contingent
which
focus
of
the entire
lower
jade
quality
mining
upon d e v e l o p i n g a m a r k e t f o r t h i s
constitutes
reserves.
i s on marketing
a major
portion
of the
jade.
operation
lower
raining
grade
In fact
may
be
material
p r o d u c t i o n and
- 3 -
Tile
manufacturing
Marketing
and b u s i n e s s
"fall-out"
from
the
and
as the focus o f the study.
arrangements
the study, butw i l l
will
certainly
come
as
n o t be c o n s i d e r e d a s p a r t o f
study.
Progression
to Facility
Marketing
Design,
Studies w i l l
the manufacturing
2.
h a s been i d e n t i f e d
preparation o f a Business
Plan,
a l l be c o n t i n g e n t upon t h e outcome o f
study.
FEASIBILITY STUDY - INVESTIGATION OF TILE MANUFACTURING
As a r e s u l t
jade t i l e s
be
o f our past marketing
must r e t a i l
competitive
reasonable
with
comparable
approximately
This
products
equates
and
t o a manufacturing
n
that the t i l e manufacturing
$45.00 p e r s q u a r e
n
cost
(ii)
What i s t h e y i e l d
(iii)
What a r e t h e o p t i m u m t i l e
(iv)
Where m i g h t t h e p l a n t be l o c a t e d ?
(v)
What a l t e r n a t i v e m a n u f a c t u r i n g
o f about
i s s u e s must be
j a d e be c u t a n d p o l i s h e d e c o n o m i c a l l y ?
from
reach
tile).
addressed.
Can l o w q u a l i t y
to
must be a c c o m p l i s h e d
foot the following
(i)
that
foot or less to
f o r sales
f o o t ( a p p r o x i m a t e l y $5.00 f o r a A x4
Based on t h e premise
for
i t h a s been determined
f o r $70.00 t o $90.00 p e r s q u a r e
volumes.
$45.00 p e r s q u a r e
efforts
the b o u l d e r s mined?
dimensions?
processes are there?
-
The
study
will
focus
possible current
2.1
on
our current
plant modification
plant
and a l t e r n a t e
configuration,
processes.
CURRENT PLANT CONFIGURATION
Conduct
an
techniques,
entire
engineering
production
existing
equipment
and
analyzing
levels
of
equipment,
individual
including
segments
individual
of the
pieces
o f the t i l e
manufacturing
"bottle-necks",
inappropriate
equipment,
total
of
process
inefficient
design.
manufacturing cost
including cost
c o s t s o f e a c h segment o f t h e m a n u f a c t u r i n g
Investigate
operating
segment
and/or i n e f f e c t i v e p l a n t
Identify
study
operation,
i n each
identifying
2.2
4 -
alternative locations for
o f raw m a t e r i a l
process.
plant.
CURRENT PLANT MODIFICATION
Identify
alternate production
e q u i p m e n t t h a t c a n be added t o t h e
e x i s t i n g equipment o r r e p l a c e
e x i s t i n g equipment.
Investigate
to
modifications
equipment t o improve p r o d u c t i o n
(Decision point
Investigate
existing
and recovery
tile
manufacturing
o f raw m a t e r i a l .
#1, s e e A p p e n d i c e s I a n d I I ) .
a l t e r n a t i v e locations for a modified
plant.
- 5 -
2.3
ALTERNATE PROCESSES
Identify
companies which
products t o jade
Identify
manufacture
equipment
working
slabs
o r comparable
tiles.
that
may be s u i t a b l e f o r c u t t i n g , g r i n d i n g ,
l a p p i n g and p o l i s h i n g jade.
stone
tiles,
business
This
e q u i p m e n t may be i n u s e i n t h e
or technology
from
unrelated
industries
w h i c h may b e a d a p t e d t o j a d e .
Identify appropriate
(i)
assist
(ii)
regulate
(iii)
g o v e r n m e n t a g e n c i e s w h i c h may:
i n e s t a b l i s h i n g the business
sectors o f the business
assist
i n identifying
appropriate
to complete equipment, manufacturing
for
be
able
initially.
jade
to
see A p p e n d i c e s
Feedback
identified
supply
input
from
t e s t i n g where
research
into
pilot
meetings
tests
tests
provide
manufacturing
t h e study
will
be f o l l o w e d
appropriate.
will
scheduled
or
should
a n d i n d i v i d u a l s who
be
done
by shipment o f
(Decision
point
#1,
I and I I ) .
organizational
design.
and marketing
organizations
The c o r r e s p o n d e n c e would
f o rpilot
further
to contact
the study.
Correspondence w i t h
may
companies
to discuss
individual
processes,
be d i s c u s s e d
topics
expertise,
necessary
materials
and
relevant
t o the
i f warranted.
These
information
flow
and a n a l y z e d
on
equipment,
and e v e n t u a l l y
plant
( D e c i s i o n p o i n t s #2 a n d #3, s e e A p p e n d i c e s I a n d I I ) .
- 6 -
2.4
REPORT PREPARATION
The
report
all
data
preparation
would
include compilation
c o l l e c t e d i nSections
Included
will
be
and analyses o f
2.1 t o 2.4.
detailed
economics
of
possible
facility
configuration including:
(i)
Capital cost
estimates
(ii)
Operating
(iii)
P r o f i t margin
(iv)
Return on investment
(v)
Estimates
cost
estimates
estimates
estimates
o f r e l a t e d mining,
e x p l o r a t i o n and t r a n s p o r t a t i o n
costs.
The
risks
supply,
associated
with
transportation,
identified
and
risk
manufacturing
analyses
i n c l u d e , b u t n o t be l i m i t e d
(i)
Jade
(ii)
Mining
(iii)
Transportation
exploration
and mining
and
completed.
and/or
marketing
These
jade
would
risks
be
would
to:
reserves/inventory/supply
costs
costs
and
losses
of
raw
and
finished
products
(iv)
Operating
c o s t s and overhead
(v)
Capital costs
(vi)
Domestic and f o r e i g n p o l i t i c s
(vii)
Marketing
risks
such
as
( i f applicable)
cost
of
sales,
distribution
(viii)
Business
(if
arrangements
applicable)
(e.g.
partnership)
advertising,
- 7 -
3.
FEASIBILITY STUDY SCHEDULE AND PERSONNEL
The
study h a s been d i v i d e d
i n t o f o u r segments:
2.1
Current Plant Configuration
2.2
Current Plant Modification
2.3
A l t e r n a t e Processes
2.4
Report P r e p a r a t i o n
The
study
The
primary functions include:
(i)
i s expected
Identification
t o extend
of
from
equipment
and
provide input into manufacturing
(ii)
Test
work,
including
mid-March
cutting,
Data
reduction
manufacturers
grinding,
and a p p r a i s a l
m i d - J u l y , 1986.
who
may
processes.
leading t o production o f a finished
(iii)
tile
until
lapping
and p o l i s h i n g
product.
o f known
technology
leading to
c o n c l u s i o n s and recommendations.
A
schedule
o f planned
i n Appendices
activities
and i n v o l v e d p e r s o n n e l
are detailed
I and I I .
Personnel involved i n thestudy
include:
(i)
B e v e r l y B l a n d - J a d e I n t a r s i a - Mohawk O i l C o . L t d .
(ii)
Joseph
(iii)
M a t t W a l d n e r - M a n a g e r , M i n e r a l s D i v i s i o n - Mohawk O i l C o . L t d .
(iv)
Eugene P l a n k - C o n s u l t a n t - C a n b i s
Additionally
of
the study.
S m i t h - M a n a g e r , J a d e D i v i s i o n - Mohawk O i l C o . L t d .
t h e r e may b e s p e c i a l t y
- Toronto,
c o n s u l t a n t s r e q u i r e d f o r segments
D e t a i l s on p e r s o n n e l and t h e i r
week i n A p p e n d i x I I .
Ontario
activities
a r e l i s t e d by
- 8 -
Three
must
go/no-go
be
plan.
decision
overcome
Costs
points
before
of
each
occur
i n the plan.
These
proceeding t o the subsequent
segment
are outlined
"hurdles"
segment
i n the
i n the f o l l o w i n g
budget
section.
4.
BUDGET
Clear
go/no-go
Feasibility
decision
Study.
points
There
have
been
defined
in
the
a r e f o u r p l a n n e d segments and t h r e e
planned
decision
points:
#1
about
the
third
week
of A p r i l
after
a
budgeted
$6,050
has
been s p e n t .
#2
about
t h e end
o f May
after
a budgeted
additional
amount
of
$33,650 h a s been s p e n t .
#3
about
has
raid-June
been
spent.
approves a f u r t h e r
Asia
a n d t h e U.S.
$30,000
If
research
after
A
a budgeted
third
additional
decision
$17,900 e x p e n d i t u r e .
may
be j u s t i f i a b l e
to
amount
proceed
o f $36,200
essentially
Travel-meeting costs i n
resulting
i n an
additional
expenditure.
into
European
Technology
identifies
a
feasible
m a n u f a c t u r i n g p r o c e s s t h e n t h i s w o u l d p r e c l u d e A s i a n a n d U.S.
to cost
results.
A m e r i c a n m e e t i n g s a l o n e w o u l d c o s t a p p r o x i m a t e l y $10,500
require
given positive
justification.
Asian
meetings
estimated
would a l s o
$30,000 e v e n
tile
and A m e r i c a n
test
and
- 9 -
The
If
budgeted
Asian
$133,800.
and
cost
of
the F e a s i b i l i t y
American
I f American
meetings
meetings
cost
i s e s t i m a t e d a t $114,300.
The
cost
details
Appendix I I .
of
each
are
Study
i s estimated at
necessary
are j u s t i f i a b l e
segment
in
the
plan
the
then
are
budget
$103,800.
rises
the t o t a l
to
study
illustrated
in
APPENDIX I
FEASIBILITY STUDY SCHBDOLB
DATS
APRIL
MARCH
10
20
30
20
10
JULY
MAT
30
10
20
30
10
20
30
PROPOSED FEASIBILITY STODT
2.1
2.2
CURRENT PLANT O0MFIGORATIQM
Appraisal of technology, plant design,
costs
ctnuonrr
PLANT MODIFICATION
Identify modifications ft/or equipment changes to current plant to
achieve targets costs ft production
s
Ship jade to positive respondents
for tests
P i l o t tests (Europe)
2.3
Identify alternate processes/plants/
equipment to achieve target costs
ft production
Ship jade to positive respondents
for tests
P i l o t tests (Europe ft Asia)
2.4
Data reductionftanalyses, options
generation, 0.8.ftAsian meetings
i f warranted
Preparation of written report with
conclusions ft recommendations.
*
Decision points to proceed with study or suspend i f responses negative.
1.
Decision to ship jade for tests only i f appropriate positive responses received.
2.
Decision to proceed with study i f any positive tests results obtained from European tests.
3.
Decision to meet with U.S.ftAsian manufacturers i f warranted from U.S.ftAsian test results ft European test results.
10
20
30
APPENDIX II
SCHEDULED PERSONNEL AND ACTIVITIES
March 10 to A p r i l 20
A p r i l 21 to May 30
Prepare l i s t of contacts for t i l e manufacturing.
Initiate inquiries ft await
Salaries for Smith, Naldner,
responses regarding manufacturing tests with equipment manufacturers ft t i l e
Consultant
producers.
Expenses
(Research ends i f no positive responses.) *1
Ship jade to positive respondents for test cutting, lapping, polishing.
results of test manufacturing.
June 1 to June 30
ft 00BT8
ACTIVITIES
TIME INTERVAL
Await
Freight ft test costs
(Research ends i f no positive respondents.) *2
Research and organise information on Mohawk's t i l e manufacturing process,
Salaries for Smith, Naldner
processing equipment, costs and plant design.
Bland
Meet with European manufacturers who have demonstrated that they are able to
Salaries for Smith, Naldner
produce tiles/slabs of acceptable quality.
Consultant
Travel ft Expenses
Reduction and appraisal of test data.
negative.)
(Research and appraisals end i f
Salaries for Smith, Naldner
Consultant
*3
Expenses
Additional meetings (Asia and/or U.S.A.) i f warranted.
(Travel ft Expenses)
July 1 to July 15
Prepare report including a l l data related to t i l e manufacturing and information
Salaries for Smith, Naldner
unearthed during the study pertinent to t i l e manufacturing, marketing,
Bland, Consultant
distribution and volume jade sales and/or consumption.
Expenses
Conclusions and
recommendations w i l l be significant, mandatory sections of the report.
* Decision Points to continue or discontinue study.
for
Note:
Require positive feedback
continuity.
(1) Consultants's expenses include 2 to 3 trips from Toronto to Vancouver return.
(2)
Salaries reduced to per diem rates and applied only when working on study.
APPENDIX I I I
MINERALS DIVISION
BUDGET DETAILS
C o s t s From Study S t a r t - u p t o D e c i s i o n P o i n t #1
Personnel:
Consultant
10 days @ 190/day «
1,900
M. Waldner
5 days @ 250/day «
1,250
10 days § 190/day =
1,900
J . Smith
Bxpenses:
( C o n s u l t a n t & misc.)
1,000
$
6,050
Costs From D e c i s i o n P o i n t #1 t o #2
Personnel:
C o n s u l t a n t 15 days § 190/day =
2,850
M. Waldner 15 days @ 250/day =
3,750
J . Smith
20 days @ 190/day *
3,800
B. B l a n d
10 days @ 100/day =
1,000
15,000
T e s t Work:
Freight:
5,000
Expenses:
2,250
33,650
C o s t s From D e c i s i o n P o i n t #2 t o #3
Personnel:
Travel:
C o n s u l t a n t 20 days @ 190/day =
3,800
M. Waldner 20 days G 250/day =
5,000
J . Smith
20 days @ 190/day «
3,800
B. B l a n d
10 days @ 100/day =
1,000
18,800
(Europe)
3,800
Expenses:
36,200
C o s t s From D e c i s i o n P o i n t #3 t o Study C o n c l u s i o n
Personnel:
C o n s u l t a n t 20 days @ 190/day =
3,800
M. Waldner 20 days § 250/day =
5,000
J . Smith
20 days § 190/day *
3,800
B. B l a n d
10 days e 100/day »
1,000
Expenses:
4,300
10,000
Contingencies
Travel:
TOTAL
17,900
(U.S.)
(10,500)
(Asia)
(19,500)
$ (133,800)
$103,800
APPENDIX I I I
B.C.
HYDRO - POWER COST ESTIMATES
B r i t i s h C o l u m b i a H y d r o a n d Power A u t h o r i t y p r o v i d e d e s t i m a t e s f o r e l e c t r i c a l
e n e r g y c o s t s a n d p e a k demand c h a r g e s .
These e s t i m a t e s were used t o d e t e r m i n e
plant e l e c t r i c a l costs.
1.
ENERGY COST
KWH
0 t o 275
276 t o 6725
6725 t o 2 9 7 2 5
+29728
2.
COST PER KWH
7.47<?
5.51<?
4.08$
2.64C
DEMAND CHARGE
KW
1 s t t o 35
36 t o 1 1 5
+115
COST PER KW
NO CHARGE
$3.13
$6.01
Power f a c t o r p e n a l t i e s may a p p l y i f p l a n t d e s i g n
inefficient.
Minimum m o n t h l y c h a r g e o f $ 1 1 . 0 9 a n d a b a s i c c h a r g e o f $ 3 . 9 1 p e r m o n t h .
Minimum c h a r g e e q u a l t o 50 p e r c e n t
b e t w e e n November 1 s t a n d M a r c h 3 1 s t .
o f maximum
demand
charge
measured
APPENDIX IV
MOHAWK JADE T I L E PLANT EQUIPMENT
1.
Do A l l M o d e l 70 1/D -
Micro
2.
S p e e d f a m M o d e l SNG 32 SPAW -
P o l i s h e r s (2)
3.
Speedfam
Lapper
4.
Dayton Speedair
5.
Do A l l S u r f a c e
6.
Bench
7.
Lapper S o l u t i o n C o n d i t i o n e r
8.
Lapper Reclaim
9.
S m a l l T o o l s , Pumps & M o t o r s , S c a l e , Washer
M o d e l SNF 48 BTAW -
Slicer
5 h.p. A i r Compressor
Grinder
Grinder
San J o s e
Tank
Tank
P l a n t items
1 - 9
$103,490.00
10.
Vertical
S p i n d l e G r i n d e r - M A S M o d e l BRV70
11.
Platform Scale
12.
H y d r a u l i c 48 I n c h D i a m e t e r B l o c k i n g Saw C o m p l e t e
W i t h One B l a d e
33,500.00
13.
Overhead Crane I n c l u d e d T r o l l i e s
15,640.00
14.
R a d i a l Arm Saw (B&D 16")
15.
G a s o l i n e Motor Powered F o r k l i f t
TOTAL
52,700.00
3,140.00
6,080.00
( F.M.V.)
2,000.00
$216,550.00
APPENDIX V
STONE-WORKING INDUSTRY COMPANIES
Wes
t g e r m a n y
Firma
Krupp-Polysius AG
Baustofftechnik
D~ 472o Beckum/W«Germ.
Planning,consultancy and
e r e c t i o n of complete plants f o r
the manufacture of b u i l d i n g
stone and s i m i l a r products.
T e l e f a x : (o2525) 71-21
Telex:
8 9 431-0
Firma
P o r s f e l d GmbH & Co B e t r i e b s KG
Hauptstrasse 3 o
H y d r a u l i c rock d r i l l i n g equipment,
c l e a v i n g u n i t s and machines;
p l a n n i n g o f complete q u a r r i e s *
0 - 8 3 9 9 R u h s t o r f ( R o t t ) W.Germ.
Telex:
5 7 283
Firma
F i c k e r t KG
Mas c h i n e n f a b r i k
Lohbachstrasse 3
D- 8 6 7 6 Schwarzenbach/W.Germ.
Telex:
6 43 818
Firma
Arbes KG
Mas c h i n e n f a b r i k
Bruchgarten 1-5
D-591o Kreuztal-Krombach/W.Germ.
T e l . : (02732)8712
no t e l e x #
Firma
C a r l Meyer KG
Steinbearbeitungs-Mas c h i n e n f a b r i k
Kraussoldstrasse 1 9
D - 8 5 9 o Marktredwitz/ W.Germ.
Stoneworking machines such aa
s a w i n g , m i l l i n g and g r i n d i n g
m a c h i n e s , s p e c i a l machines,
complete production l i n e s ,
g r i n d i n g , p o l i s h i n g and c u t t i n g
d i s c s f o r stoneworking.
Stone-cutting, multiple-blade
saws, frames, stone gang saws,
c i r c u l a r stone-saws and stonem i l l i n g machines.
b a s i c same f a b r i c a t i o n
l i k e F i c k e r t KG
rpoducts
T e l e x : 6 41 274 meyer d
Firma
A* Volkenborn Maschinenfabrik
B u i l d i n g s i t e c i r c u l a r saws
Hauptstrasse 13
and masonry saws
D- 5620 V e l b e r t l l ( L a n g e n b e r g ) W.Germ.
T e l e x : 8 516 717
A u s t r i a
Manufacturers of machinery f o r stoneindus t r y
U n f o r t u n a t e l y the a u s t r i a n l i t e r a t u r e and l i b r a r y i n f o s
are not s p e c i f i c to f i n d out, which p a r t i c u l a r machine
they produce, Basic any type o f specialmade equipment f o r
s toneind\Ary •
#
Firma
Johann Leinweber
Industriegelaende Nord
A-27oo Wiener N e u s t a d t / A u s t r i a
Firma
Austrcplan
O e s t e r r .Planungsges •m,b,H.
Linke Wienzeile 234
A-1150 Wien/ A u s t r i a
Firma
Anderle K a r l
Werkzeugmaschinenbau
G l e i n k e r Hauptstr.3
A-44o7 S t e y r / A u s t r i a
Firma
Mannsberger Eduard Ing.Ges.n.b.H.
Hauptstr. 44
A-2544 L e o b e r s d o r f / A u s t r i a
Telex:
0I6-657
T e l e x : 1 32997
T e l e x : no
T e l e f o n : 07252/ 632
Telex:
63
ol4-446
Wes
t g e r m a n y
Firma
Otto Suhner GmbH
Bauvereinstr,13
D - 7 8 8 0 Bad Saeckingen 1/Kest e r m .
G
T e l e x : 7 92 32o
F l e x i b l e shaft-machine
tools f o r stone-dressing
t o o l s and attachments f o r
the f o r m e r , d r i l l feed
u n i t s , special-purpose
machines.
Firma
KKD Humboldt Wedag AG
Wiersbergs t r a s s e
D-5ooo Koeln 91/W.Germ.
T e l e f a x : (o221) 8 23-72 4o Group 3
T e l e f : (o221) 8 23-0
Telex:
8 812-0
This company i s s p e c i a l i s e d i n :
Machines
and plants f o r p r o c e s s i n g raw m a t e r i a l s and
p l a n t s f o r the p r o d u c t i o n o f quarry products .
minerals,
Most of the companies on page -1- are a l s o i n v o l v e d i n s e t t i n g
up of complete plants and p r o d u c t i o n s t r e e t s f o r the stone
industry.
I f you need more informations i n the m i n i n g i n d u s t r y , concerning
the Jade-quarry by i t s e l f , p i s . l e t me know.
These would be complete d i f f e r e n t types of manufacturers.
Wes
t g e r m a n y
Firma
M a r t i n Kolb
Mas chinenbau
Zeughausweg 26
D-79o5 Dietenheira i/W.Gernu
S t o n e c u t t i n g machinery
T e l e x : 7 12 295 k o l b d
Firma
Eisenwerk Hensel Bayreuth
D i p l , I n g . B u r k h a r d t GmbH
K a t h e n a u s t r a s s e 47
D-852o Bayreuth/ W.Gerra. '
complete l i n e o f stoneworking machinery and t o o l e s .
T e l e x : 6 42 823
Firma
Robert S c h l a t t e r GmbH k Co
Mas c h i n e n f a b r i k
D e t t i n g e r Str.82
D^7312 Kirchheim(Teck)
Tel.:
Machinery f o r working n a t u r a l
and a n t i f i c i a l s t o n e .
(o7o21) 5 47 3o
Firma
P e t z i n g k Hartmann
Mas c h i n e n f a b r i k GesnbH & Co KG
L e i p z i g e r S t r . 153-163
D-35oo Kassel-Bettenhausen
Pehaka-bandsaws f o r a l l sawing
problems, and sawing i n s t a l l a t i o n *
T e l e x : 9 9 668
Firma
Schindler
Steinbearbeitungsmas chinen
A n l a g e n t e c h n i k GmbH
Donaus t a u f e r s t r , 15 o
D-8400 Regensburg/W.Germ.
Machinery and p l a n t f o r s l a b s
and s t e p s .
T e l e x : 6 5 639
Firma
Helmut Darda
Maschinenbau
D-7712 Blumberg(Baden) l/W Germ,
#
T e l e x : 921 219
B u i l d i n g f.above-ground b u i l d g .
and c i v i l underground working;
rock-splitters