By Cepicat
In the stone fabrication industry, the edge finish is the signature of quality. Whether processing natural stone, quartz, or sintered surfaces, achieving a flawless, mirror-like polish on automatic edge polishers—such as those by Comandulli or Montresor—requires a perfect synergy between machine calibration and abrasive technology. At Cepicat, we recommend a specialized protocol to master the edge polishing process, utilizing an optimized 7-step abrasive system.
At Cepicat, we recommend a specialized protocol to master the edge polishing process, utilizing an optimized 7-step abrasive system.
1. Machine Calibration: The Foundation
Before running the first piece, the mechanical setup must be precise. Based on industry benchmarks for machines like the Comandulli Omega or Montresor Luna, here are the optimal parameters:
- Conveyor Speed: For high-quality polishing, a speed between 20 cm/min and 45 cm/min is recommended, depending on the machine model. Slower speeds (20-25 cm/min) allow for a deeper chemical bond during the final polishing stages.
- Pressure Management: Pneumatic pressure is critical. We recommend a "sweet spot" of 2.5 to 3.0 Bar. This provides enough force for the abrasives to work without crushing the segments or burning the resin.
- Water Flow: Ensure center-water feed is unblocked. Inconsistent cooling causes the resin wheels to overheat and smear, ruining the shine.
2. The Cepicat 7-Step "Premium" Protocol
The secret to a perfect finish lies in the specific function of each spindle. We utilize a specialized 7-position setup designed to transition from aggressive shaping to a high-temperature chemical-mechanical shine.
Phase I: Shaping and Calibrating (The "Hot" Zone - 140°C)
These steps are critical for geometry. The abrasives in this phase are developed to work at 140°C
- Position 1: HAMMER
- Function: This wheel is the workhorse. It removes raw saw marks and creates the initial profile. On a Comandulli, ensure this spindle is perfectly aligned to avoid creating a "step."
- Position 2: CALIBRATOR
Function: Refines the deep scratches left by the Hammer. It defines the bevels (chamfers) and prepares the surface geometry.
Phase II: The Crucial Middle (140°C)
- Position 3: TRANSITION
- Function: The bridge between rough grinding and polishing. It eliminates the risk of "pigtails" or visible scratches under the final shine.
- Position 4: SATIN
- Function: Leaves the stone with a smooth, matte finish. The surface should feel silky to the touch.
- Position 5: BASE SHINE
- Function: The first sign of reflection appears here. This wheel establishes the depth of color. Phase III: The "Wet Loo
Phase III: The "Wet Look" Finish (The High-Temp Zone - 160°C)
For the final gloss, we increase the thermal requirement. These positions operate best when the friction generates a temperature of 160°C, allowing the resin to vitrify the surface.
- Position 6: DEPTH
- Function: This wheel clears the haze. It utilizes a specific resin formulation to bring out deep blacks and vibrant colors.
- Position 7: MIRROR
- Function: The final seal. It provides the "glassy" effect. On Montresor machines, ensure the oscillation is smooth to avoid marks
3. Troubleshooting Common Issues
- Issue: Horizontal Lines (Scratches)
- Cause: Usually a skipped grit or a damaged wheel in Pos 1 or 2 (Hammer/Calibrator)..
- Fix: Check the first two wheels for glazing or wear.
- Issue: Hazy Finish (Milky appearance)
- Cause: The "Transition" (Pos 3) or "Base Shine" (Pos 5) didn't work long enough.
- Fix: Slow down the belt speed to the lower range (approx. 25 cm/min) or slightly increase pressure..
- Issue: Burnt Edge / Plastic Smears
- Cause: Lack of water or excessive pressure (over 4 Bar) on the final positions.
- Fix: Verify water nozzles are aiming at the contact point and keep pressure under 3.0 Bar
- Cause: Lack of water or excessive pressure (over 4 Bar) on the final positions.
Conclusion
Machines are engineering marvels, but they are only as good as the abrasives they drive. By respecting the specific role of each Cepicat position—from the Hammer to the Mirror—and maintaining the correct pressure parameters, you ensure a consistent, factory-quality finish that sets your fabrication shop apart.