For decades, the rhythmic sound of the Gang Saw was the heartbeat of every marble factory. It was slow, steady, and reliable. But the industry is changing. The rise of Multi-Wire technology has disrupted the status quo, offering speed and flexibility that traditional methods can’t match. In this technical analysis, we compare the two giants of block cutting to help factory owners decide: Is it time to upgrade?
1. Speed & Productivity
- Gang Saw: The tortoise. It can take 8 to 12 hours to cut a block depending on hardness.
- Multi-Wire: The hare. Drastically faster cutting times. A block can be sliced in a fraction of the time, allowing for “Just-in-Time” production strategies.
- Verdict: If speed is your priority, Multi-Wire wins hands down.
2. Flexibility
- Gang Saw: Rigid. Changing slab thickness (e.g., from 2cm to 3cm) requires a complex setup change. You usually cut the whole block in one thickness.
- Multi-Wire: Agile. You can easily adjust wires to cut different thicknesses from the same block or cut only half a block if needed.
- Verdict: Multi-Wire offers superior adaptability for custom orders.
3. Surface Quality & Waste
- Gang Saw: Provides a very flat surface but uses steel grit and water, creating a muddy sludge that is hard to dispose of.
- Multi-Wire: Uses diamond beads. Cleaner cut, less sludge, but requires precise tension control to avoid “wavy” slabs.
4. Cost Analysis
| Cost Factor | Gang Saw (Traditional) | Multi-Wire (Modern) |
|---|---|---|
| Initial Investment (CapEx) | High (Requires heavy foundations & large space) | Medium-High (Expensive machine, but smaller footprint) |
| Consumables Cost | Low (Steel blades, lime, grit) | High (Diamond wires are pricey) |
| Energy Cost (Per Slab) | High (Long cutting duration: 8-12 hours) | Low (Fast cutting: 1-2 hours) |
| Waste Disposal | Expensive & Difficult (Chemical sludge) | Manageable (Water + Stone dust) |
| Maintenance | Simple mechanical maintenance | Requires skilled technicians |
- Initial Investment: Multi-Wire machines are often more expensive upfront.
- Running Costs: Diamond wires are a high consumable cost compared to steel blades + grit. However, the energy cost per slab is often lower with Multi-Wire due to speed.
(Conclusion) The Gang Saw is not dead; it remains the champion for processing massive quantities of uniform slabs at a low consumable cost. However, for the modern factory that needs speed, flexibility, and cleaner operations, the Multi-Wire is the inevitable future.
Industry Insight: Many factories are now adopting a hybrid model—keeping gang saws for bulk orders and using multi-wire for urgent, high-value exotic stones.
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