Production Processes during Processing Phase

The processing phase is characterized by arrival of the raw excavated stone at processing units where it undergoes a variety of procedures that result in (a) semi-finished dimensional blocks or (b) finished end products (tiles, slabs, decorative items, mosaic, chips, marble powder and others). For both (a) and (b) the initial steps of the production process are almost the same. Narrating these steps manager of a processing unit in PeMaS stated;

„As the stone arrives from mine a crane unloads it. If the stone is large that is a block we use the same crane to place it on the gang saw for initial cutting. If the stone is small for instance half block or boulder the crane is used to place it on vertical cutter‟

Most cranes used in processing units are fixed to the ground positioned near the stone cutting machinery. Cutting of the stone is the first step in the processing phase however this cutting can be of various types and forms depending on three major types of cutting equipment/machinery the processing units in PeMaS and BuMaS have;

a. Gang Saw b. Vertical Cutter c. Horizontal Cutter

All three types of machinery use electricity. There is considerable usage of water during the cutting process to reduce the cutter and blades from excessive heating due to high friction. The gang saw has a large metallic or iron platform fixed to the floor with enough space to accommodate a raw marble block. The main feature of the gang saw is 5 – 9 horizontal blades that cut through a block simultaneously. The cutting process starts from the top of the block with blades moving down vertically. This results in 6 – 10 large marble slabs. These slabs undergo further procedures described later in this section. Another type of cutting machinery more common than gang saw is the vertical cutter or ‘vertical’. The vertical has either a flexible arm or platform allowing movement mostly in one direction only (forward and backward). The machine operator uses manual handles to move the stone on the platform.

The ‘vertical’ offers lesser efficiency compared to a gang saw. The main

feature of the vertical cutter is a single circular blade installed vertically onto a metallic arm which the worker uses to cut the stone vertically. A vertical is more useful for cutting half blocks and boulders but can be used for cutting blocks as well.

The third type of cutting machinery is the horizontal cutter or ‘horizontal’. It is very similar to a ‘vertical’ in terms of basic features. The only difference also evident from the name is that it cuts the stone from left to right or vice versa characterized by horizontal movement of the blade. Vertical cutting takes place prior to horizontal cutting. The ‘vertical’ and ‘horizontal’ both perform a similar function termed by the respondents as ‘sizing’. An additional feature of

‘horizontal’ is that it is used for thinning slabs or tiles to pre-determined sizes measured in ‘sutar’, mentioned in Section 9.2.2. Vertical can be used to straighten the four sides of slabs or tiles. The ‘vertical’ and ‘horizontal are also’ used to manufacture semi-finished dimensional blocks. Compared to gang saw which is more suitable for slabs measuring between 3 and 8 feet, the ‘vertical’ and ‘horizontal’ are more suited for producing tiles and can cut them in sizes ranging from 1/3 ft to 2 ft. However, there are no standardized sizes for each type of cutting equipment. Describing these processes the owner of a processing unit in PeMaS said;

„…at the factory we take out slabs of 9 „sutar‟ thickness. From that slab we produce tiles of 1 sq. ft., 1 ft. x 2 ft., ½ ft. x 1 ft. and 1/3 ft. x 1 ft. Then we take these tiles to another machine, the Horizontal that cuts each tile from the middle to convert 9 „sutar‟ thicknesses to two tiles of 4 „sutar‟ thickness each‟

A key characteristic of the above-mentioned cutting machinery is use of cutting blades termed as ‘tips’ by respondents. These ‘tips’ are installed on the circular blades (both vertical and horizontal) or gang saw cutters by experts who specialize in this area. The quality and prices of the tips are mainly influenced by durability. Elaborating on ‘tips’ a middleman in PeMaS who specializes in ‘tip’ instalment pointed out;

„Most cost in terms of equipment in marble processing is borne on blade tips.

These tips are coated with diamond dust or particles to give them the sharp

manufactured locally…local tips work for one month, Italian can last up to six months but is more expensive‟

The slabs and tiles of varying sizes and shapes are put through another process called ‘polishing’ to enhance the overall appearance of the product.

The polishing machine or ‘polisher’ is used for this purpose. Most processing units in PeMaS and BuMaS have a ‘polisher’ installed at the factory. This equipment has special kind of ‘grinding stones’ of varying contours that are abrasive in nature. These stones reduce unevenness of marble’s surface.

Combined with a special kind of polishing wax or dry soap the last step of the polishing is performed that results in a much cleaner, smoother and shinier end product. Most polishing machines are locally manufactured. Describing this equipment a middleman and sector expert with 20 years of experience stated;

„The Pakistani polishing machine which is manual in nature gives you 100 to 200 sq. ft of polished tiles in 8 hours…these local polishing machines cost about Rupees 0.1 to 0.2 million. It does not give the same value or quality.

The imported polishing machine...can give 800 to 1000 sq. ft. in 8 hours…imported machine is Rupees 6.0 to 7.0 million…the price difference is very obvious‟

Some processing units also produce decorative items, mosaic, chips and marble powder. The raw material for decorative items is the semi-finished dimensional block and the most common equipment/machinery used for this purpose is called the ‘Lathe’ machine. The ‘Lathe’ spins the marble block to perform various operations on it including cutting, sanding, knurling, drilling or deformation. It enables the craftsmen to produce items like ashtray, vase, cups, plates, mosaic and others. For marble chips a special kind of crusher is used in processing units. All small stones that are scrap material resulting from cutting process using gang saw, ‘vertical’ or ‘horizontal’ are used in the crusher. However, many processing units approached for data collection did not have a crusher to produce chips. Similarly marble powder also results from the cutting of stones.

The processing phase also involves significant involvement of workers. They are involved not only in manually supporting the cranes to place stones on cutting machinery but also operate these machineries as well as polishers.

However, the level of skills and craftsmanship required for producing decorative items is higher than producing slabs, tiles and chips

.

Deriving from these discussions Figure 9.2 provides different phases of production processes.

Figure 9.2: Illustration of Production Processes during Mining and Processing Phases in PeMaS and BuMaS

Polisher, Grinding Stone, Wax, Water Manual Labour:

Position slab/tile on to platform Apply grinding mechanism, wax, water Output:

Finished slabs and/or tiles

STEP I Designing

Equip. / Material: Manual Labour: Output:

Lathe Machine Crafting designs Decorative