Giben Icon Fast - Insustrial Panel Saw #1: Why-How-When

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Blog entry by Mainiac Matt posted 10-22-2019 04:15 PM 383 reads 0 times favorited 2 comments Add to Favorites Watch
no previous part Part 1 of Giben Icon Fast - Insustrial Panel Saw series Part 2: big trucks and heavy skids »

The company I work for has purchased and is setting up a rear loading, auto-feeding, heavy duty industrial panel saw (often called beam saws) and I thought the LJ crowd might enjoy exposure to what’s out there in the high volume industrial wood working world.

While most often you’ll see this type of equipment in high volume cabinet shops (one of the service techs tells me that Merillat has TEN similar machines) I work at an industrial packaging company and we use this equipment in our panel shop that supports both our crating and case fabricating departments.

This will be the 4th beam saw we’ve owned (2 SELCOs and a Holzma), with all the previous machines being purchased very, very used at auction. We currently have one SELCO in service (others are long gone) that is a front loading manual feed machine.

And while it currently runs well and meets our current production needs, we have two problems with it. First, this saw is a critical non-redundant asset for our operation and it’s getting long in the tooth. The electronic controller is no longer supported by the manufacturer (Biesse) and to upgrade it to current technology would cost ~$30K + flying a tech. in from Italy. So after some research, I couldn’t recommend that we put that kind of money into a 20 year old machine. Second, our company is very well positioned in the market place for growth, and if we can make good on our plans to grow the company, we will need more cutting capacity.

Though Giben was originally an Italian company, they now manufacture in Tawain and are priced very favorably when compared to the European manufacturers. Giben now has the panel processing division of Anderson (Top end industrial CNC machinery) under their auspices, so we negotiated the simultaneous.purchase of two machines, the Icon Fast and a G4 CNC router with auto-panel feed and auto table clearing. I think we got a really good deal. The G4 was in the warehouse and was installed back in June. The Icon Fast was custom built to our spec. and we just took delivery of it after waiting four months.

Here’s the cleared out area of our panel shop…

And the 20 HP, 7,000 CFM dust collector that services both the G4 and the new Icon Fast.

You can see we already have the DC header plumbed and ready (all Quick Duct with a 12” header) and have power going to a disconnect at a newly installed power pole.

Infrastructure requirements for the saw are:
>150 psi dry, filtered service air.
>60 amps 480 v 3 phase power
>Dust collection capacity of 3,500 cfm

Because of the two new Gibens, and a new Baker double head resaw (installed in the spring) we had to upgrade our 480 service to this shop earlier in the summer from 400 amps to 800 amps (a measly $10K investment).

The weight of the main unit (and it turns out the largest skid of steel frames) were both beyond the capacity of our largest fork truck (an 10,000 lb. rated Hyster)

So we had to hire professional riggers. We used National Machinery Movers out of Hooksette, NH for both the G4 install and today’s job. This is their “small” lift. It’s a custom low boom rig with an telescoping ballast. It can pick 25,000 lb. with the ballast in, and 35,000 with it out (as shown here). I’m told this is a $300,000 fork truck.

We installed a couple other very heavy machines two years ago, and after watching our maintenance crew struggle with the rigging (yah…. it was scary to watch) I insisted that we had to hire riggers for these jobs. It’s just not worth the $ saved to risk damaging the machine… and both of these are precision automated builds with lot’s of moving parts.

-- Matt -- I yam what I yam and that's all what I yam

2 comments so far

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Mainiac Matt

9348 posts in 2865 days

#1 posted 10-22-2019 04:34 PM

Here’s some of the machine specs…

main saw blade is 18” in diameter and has a 25 HP motor. This big boy spins at 4,000 rpm for a tip speed of 18,840 fpm.

scoring saw blade is 7” in diameter and has a 3 HP motor.

there are multiple 3 HP servo motors that drive the saw carriage and control the panel feed, etc…

total machine weight is 23,100 lbs.

we purchased the saw with an 11’ wide throat. So we can easily rotate 8’ panels on the deck (for the cross cut) and can still break down 10 panels (which we rarely do on the panel saw… we load 5×10 sheets directly onto the CNC router when we use them).

-- Matt -- I yam what I yam and that's all what I yam

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6066 posts in 2257 days

#2 posted 10-22-2019 11:41 PM

Looks exciting! When I worked in plastics recycling I thought the riggers had big fork lifts when we installed new shredders and granulators. I later worked in a temper mill where some coils could be at or slightly above 80Klbs. Those fork lifts were really big, the pickle/slitting line in the plant next door had one that was good for 140Klbs., I think the plant manager told me a brand new replacement was 1.2M as equipped.

-- "Lack of effort will result in failure with amazing predictability" - Me

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