With a whole new generation of engineered stones that require a different set of tools to work, life is becoming complicated for processors.

For a live demonstration of diamond tools made specifically for processing Dekton, the new sintered stone from Cosentino, the place to be was the Diamut stand in Hall 3 of the Marmomacc exhibition in Verona 24-27 September. Diamut, the diamond toolmaker owned by machinery company Intermac, presented its new range of Cosentino-certified tools for the machining of Dekton.

Diamut has developed a complete range of tools for drilling, cutting and profiling the new material.

The quality of these tools has been tested at length in collaboration with Intermac and finally submitted to the technical department of the Cosentino Group, which officially approved the performance and finishing quality obtained through the certification of the tools’ operative parameters.

At the base of this result there is the development of a dedicated bond for tools used for processing Dekton, which offers extreme profile-matching between diamond and polishing wheels.

To complete the offer, a new dedicated buffing wheel has been produced that gives high quality polishing of the finished piece.

But Diamut is not alone in offering tools specifically for sawing, polishing, drilling and routing the new generation of engineered stones. Most of the major makers – ADI, Diamant Boart, Nicolai, Tyrolit and the rest – had their own versions on show at the Italian exhibition. But there were also a lot of smaller companies exhibiting, including some from China and other parts of the Far East, some of whose products are sold in the UK, often by smaller local tool sellers looking for a competitive advantage.

The fact that the new sintered, glass and ceramic products need different tools to be worked on CNC saws and workcentres is making some processors think twice about getting involved with the products. The makers of the materials think they can create enough demand from designers and end users to leave processors with no choice but to encompass them – after all, it worked with engineered quartz. Some processors, especially (but certainly not exclusively) in London, have already taken the new products on board, seeing them as an opportunity to win a greater share of the market.

According to those already processing Dekton, Cosentina’s new sintered product, if you try to use the same tools that are used for working granite, the edges of the material can chip. And making draining grooves or sunken drainers can be difficult because Dekton does not behave like stone. The new materials also wear standard granite processing tools at a rapid rate.

Lapitec has taken the view that it will supply tools for working its sintered material. The material is being sold in the UK by the stone wholesaler the Marble & Granite Centre in Rickmansworth, Hertfordshire, which is also selling the tools – and the range on offer is gradually growing, although it already includes saw blades, routers, finger bits and drills.

Some processors say they are cutting sintered products most successfully using more sophisticated saws with inverters. Others report that the materials are so hard they have blown the backs out of core drills after a few holes. Others report that any wear on the saw bridge can set up vibrations that can end up damaging the edges of the cut. If the speed is lowered to prevent the vibrations the disc does not last long. There is clearly some trial and error taking place among processors looking for the ideal solution.

Stella Zambelis, of UK machinery, tools and consumables supplier D Zambelis sells Cidiam and Nicolai diamond tools and has saw blades of 400, 450 and 500mm for sawing sintered material and hopes soon to have a 350mm blade on offer.

She currently has the Cidiam blades on trial with some of her customers and says they seem to work well as long as they are used at the speeds recommended on the blades, which is not always possible with smaller, less sophisticated saws. She says she will await the end of the trials before putting the blades on general release.

Nevertheless, clearly the toolmakers believe the new materials are presenting them with an opportunity to expand sales because most of them are producing ranges for the new sintered stones. Stella agrees. She thinks demand will pull stone processors into working the new materials and says: “When more people start using it we will be ready to supply them. I have customers say they won’t bother with it, but people used to say that about quartz and now it’s typically 50% of their work.”

And Stella says it is not only the new forms of engineered stone that are testing the tool makers. Red Iron granite, which is even harder than black granites, is also giving processors a problem. “One of our customers told me it took them an hour to make a 3m cut,” says Stella. Zambelis also sell Cidiam blades for cutting Porcelain, which they have also sold for cutting the sintered materials. “They’re not perfect but at least they keep working,” says Stella.

Diamant Boart, the Belgian toolmaker, has just moved into new premises in the UK near to its old premises in Leeds and it would be delighted to have a company such as Zambelis selling its range of CNC tools to processors it does not have the resources to service directly. Duncan McLean, who heads Diamant Boart’s activities in the UK, invites any wholesaler who would like to sell the CNC tools to call him (07753 811046).

Diamant Boart’s traditional customer base in the UK (mostly sandstone companies in the North of England) are keeping it fully occupied. There have been major developments in wire sawing at Diamant Boart in recent years (as there have among other major manufacturers) and gradually the big sandstone processors are moving over to wire sawing, with some now investing in multiwires. In fact, as we reported in the previous issue of NSS, Forest of Dean Stone Firms has already bought a five-wire Pellegrini and the wires it is using are from Diamant Boart.

As well as moving into new premises, Diamant Boart has recruited a new salesman in Allan Cork, previously with Saint-Gobain’s diamond tooling company Nimbus, which has now pulled out of the market.

Stonegate gives you Status

Stone tool supplier Stonegate is the sole UK agent for the new Status Diamond Tooling range of precision CNC products, adding to the already impressive catalogue of stone cutting tools from Stonegate.

Status is a brand internationally recognised for providing high quality tools and materials at competitive prices, combining strength and quality. The tools undergo rigorous quality control to ensure they cut with great precision and have a long life.

Every product is quality inspected before leaving the factory to ensure it meets demanding standards and that customers receive the best possible products only. The tools are used by some of the leading stone companies and Stonegate believes Status will be the brand of choice in the UK for professional stone cutters.

Stonegate has designated a team to work with purchasers of the Status products to ensure they are buying the right tools for them.

Stonegate will sell the Status products alongside brands such as Nicolai and Diamut, which it also supplies, including ranges designed specifically to cater for the growing demand for tools to process engineered stone and the latest generation of engineered worktops.

The sintered products, such as Dekton and Lapitec, are fast becoming popular materials for both domestic worktops and commercial work surfaces. Even though these materials can be difficult to work, Stonegate offers a number of blades specifically for such products that help ensure a nice clean, chip-free cut.

The Cherokee large porcelain blade has been designed for bench saws and its larger spaced gullets and water channels help lubricate the cutting edge, ensuring a clean cut with minimal chipping and flaking combined with long product life.

Drilling tap holes can also be something of a headache in the new products. However, Stonegate’s wide range of thin wall drills are ideal for making clean, accurate holes with no chipping or flaking.

The company also offers the FB23 router – ideal for the new sintered products. It has a soft bond which exposes the diamond quickly, keeping the tool sharp and cutting cleanly.

Stonegate Tooling has continued to listen to customers’ needs and is planning more product launches throughout the rest of the year. With its next day delivery service, it says it is currently achieving 98.5% complete orders on all standard stock items.