International Forest Industries Magazine Aug Sept 2013 by International Forest Industries Ltd

VOL ONE

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ELMIA REVIEW ISSUE – PART TWO

CONTENTS

AUGUST/SEPTEMBER 2013

41 Shredders & Grinders: International Forest Industries’ reporter Paul Moore looks through some of the more durable size reduction equipment on the market that is being applied largely for the business of recycling

20 Scanning & Optimisation:

53 Skidder Technology:

This year’s Scanning & Optimisation technology review could be the precursor to some true revelations for the sawmilling sector in the years to follow

Stronger markets doesn’t mean frivolous forestry practices, according to several leading skidder suppliers that continue to focus on keeping fuel costs and maintenance time down, while keeping the machine in the forest longer

36 Scanning & Optimisation – Operation Focus: The East Alabama Lumber company and industry partner Autolog early this year challenged themselves with a seamless installation and commissioning of a state-ofthe-art optimisation system

International Forest Industries took the opportunity to visit local Swedish success story, Rottne, in the lead up to Elmia to get an advance look at the new technology that would be on show and see how the team puts together a range of machines that has grown to challenge some of the biggest in the industry

4 Sawpoints

12 World Markets

32 Scanning & Optimisation Operation Focus: USNR’s Transverse High Grader (THG) made its debut recently grading the very challenging green douglas fir at a dimension lumber mill in Oregon.

62 High Profile – Rottne:

60 Company Focus – Rottne:

50 Shredders & Grinders – Operation Focus: Morbark

R EG U L A R F E AT U R E S

International Forest Industries Editor Chris Cann shared a bench on the Rottne stand at Elmia with Managing Director Rolf Andersson and discussed his life in the forestry, the emergence of Rottne as an international power, and the importance of a holiday

70 Cutting Edge

72 Advertising Index

COVER: HewSaw SL250 3.4 – Sawing Line with all the modern features The HewSaw SL250 3.4 is the most diverse and flexible sawing line in the HewSaw product family. The structure and automation of the line facilitate efficient sawing with a high lumber recovery factor. The modern multi-phase measurement and optimization system is also suitable for scan and set sawing. These sawing

lines can efficiently process logs between 80 to 420 mm (3-inches and 16.5 inches) in diameter at the top end and up to 550 mm at the large end. More information on HewSaw products is available at www.hewsaw.com

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OPERATION FOCUS ISSUE 35 AUGUST/SEPTEMBER 2013

SUBSCRIPTIONS Tel: +44 (0)1442 877 583 emma@internationalforestindustries.com Annual Subscription UK and Europe £160, €230 Rest of the world US$270 EDITORIAL T: +44 (0)1442 877 583 F: +44 (0)1442 870 617 www.internationalforestindustries.com 2 Claridge Court, Lower Kings Road Berkhamsted, Herts. HP4 2AF, UK Editorial Director John Chadwick john@internationalforestindustries.com Editor Chris Cann chris@internationalforestindustries.com Editorial Board Dr Patrick Moore – Chairman and Chief Scientist of Greenspirit (Canada) Darren Oldham – Managing Director Söderhamn Eriksson (UK) Allan Hansard – Chief Executive of the National Association of Forest Industries (Australia) Professor Piotr Paschalis-Jakubowicz – Warsaw Agricultural University (Poland) Andre de Freitas Forest Stewardship Council Head of Operations Eduardo Morales South American Forestry Consultant ADVERTISING AND PROMOTIONS Lansdowne Media Services Ltd Advertising Manager Phil Playle phil@internationalforestindustries.com Group Advertising Manager David Lansdowne david@internationalforestindustries.com +44 (0)1442 87 77 77 Design & Production CSDA – csims@nildram.co.uk Associate Editor Robin Peach robin@internationalforestindustries.com Advertising Production Enquiries Emma Smith emma@internationalforestindustries.com International Forest Industries is published by International Forest Industries Ltd, 2 Claridge Court, Lower Kings Road Berkhamsted, Herts. HP4 2AF, UK International Forest Industries (ISSN 1755-6732) is published monthly by International forest Industries Ltd GBR and distributed in the USA by SPP, 17B S Middlesex Ave, Monroe NJ 08831. Periodicals postage paid at New Brunswick, NJ. Postmaster: send address changes to International Forest Industries, 17B S Middlesex Ave, Monroe NJ 08831. © International Forest Industries Ltd 2007 – 2012 IFI uses, as preference, SI units throughout. All dollars are US unless otherwise stated.

EDITOR’S COMMENT

Sharpen your blades

awmillers as a group have probably been driven to give up reading over the past few years. The mainstream press has carried generally upsetting news of recession, economic crisis in Europe, and flat numbers for the all-important US housing market, while industry publications like this one have had little positive sawmilling news with which to fill their pages – for a short while in 2009 it seemed every second story outlined the demise of a sawmill or sawmill supplier. Then things went quiet. The sawmilling sector lost its voice. Management energies were directed toward cost cutting and efficiencies. Those left standing were pleased to be around but remained in survival mode. Austerity was not just a buzzword for European politicians. But earlier this year, through the mouthpiece of Ligna in Germany, murmurings were heard from the sawmilling industry once more. New technology was released. New installations were announced. Fresh contracts were signed. In this edition of International Forest Industries, there is again plenty of content that would urge the sawmilling community to reach for their collective reading glasses. World wood markets are responding to an uptick in demand for sawnwood products. The US housing market is strengthening, which, along with generally better economic data out of the world’s largest economy, has increased the demand for sawnwood products. This has been particularly true for domestic suppliers but Canadian sawmills are also cashing in on the US recovery – Canadian mills are expected to enjoy a doubling of pre-tax profits in the current year. Also adding to the good mood in Canada is the return to form of China. Canada joins Russia as the leading

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suppliers of sawnwood products into the Chinese market. The world’s most powerfully emerging economy had been in relative hiatus, prompting many economists to predict a major and lasting slowdown in its growth. This slowdown now seems to have been overestimated. Even more encouraging has been the response from European sawmills to China’s resurgence. The EU, typically not a big player in Southeast Asian markets, accounted for 8% of shipments into China in the June quarter. Growth in the EU remains flat but stability has returned. Backing up the hard numbers has been comment from suppliers. Those IFI has spoken to over the past couple of months have showed optimism absent for years. More commanding has been their actions – there has been a major upturn in the engagement of the sawmilling industry with the press to promote new technologies and installations. If the past five years has taught us anything, it is to expect the unexpected. But it is difficult to ignore the mass improvements for sawmills, sawnwood pricing, and sawmill technology. Such a uniform step forward is the best indication – and possibly only indication – we’ve had that the sawmilling industry is due for a period of much brighter days. Enjoy Chris Cann E D I TO R

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SAWPOINTS

Deere strengthens European presence and appoints CTL specialist John Deere Forestry is responding strongly to changes in the forestry markets, as well as driving Deere & Company’s strategic initiatives to enhance focus on forestry customers and to deliver increased customer value by expanding and strengthening its distribution network in Europe with three new dealers

n Bulgaria, Sofiaheadquartered Megatron has a long history of serving as John Deere’s exclusive Agricultural and Turf equipment distributor since 1998. The company employs about 100 people in seven locations and 22 service points in Bulgaria. In addition to John Deere equipment, Megatron also distributes attachments and construction machines. The company’s mission is fully aligned with that of Deere & Company – to provide customers with the most reliable, efficient and cost effective solutions and the highest level of after-sales support. In Portugal, Pinto & Cruz Motores e Equipamentos has been appointed as John Deere Forestry’s new country-wide distributor. The mother company, established in 1935, is active in many fields of engineering services, such as heating, lifts, engines and pipes. The company employs some 400 people and has several offices in Portugal, Angola and Mozambique. Pinto & Cruz Motores e Equipamentos has

sales and service facilities in Oporto and Benavente. In addition to John Deere forestry equipment, the company distributes cargo handling equipment, engines and gensets, as well as smaller-scale forest and garden equipment. Öforst Forsttechnik, John Deere’s forestry equipment distributor in Austria since 2009, has been appointed as sole distributor for Hungary. The company employs 14 people and has its headquarters in Judenburg, Steiermark. Besides John Deere equipment, Öforst Forsttechnik distributes forestry attachments, forestry excavators and forestry tractors. Despite its relatively short history as a Deere distributor, the company has already been granted John Deere’s ‘Dealer Excellence Award’ for its exceptional customer support performance. In Hungary, Öforst Forsttechnik will have Hungarian-speaking sales and service staff, as well as two local service partners. Further support is provided by the existing and proven organissation in

Austria. “Europe continues to be a primary market area for our equipment and, along with the development of the European economy and forestry practices, we are expanding our distribution to new markets and enhancing our customer service and satisfaction in existing markets,” Janne Märkälä, John Deere Forestry General Manager, Marketing & Order Fulfillment, said. “All the above new distributors are professional and sustainable businesses, with a high level of customer orientation, and perfectly aligned with John Deere’s distribution philosophy.” Meanwhile, Timo Ylänen has been positioned as Director of Worldwide Wheeled Cut-To-Length Products & Forestry Europe. Ylänen started in the rolein July and is responsible for all aspects of Deere’s forestry business in Europe, as well as the stewardship of the Wheeled CTL product lines globally. The position is being established to enhance the company’s focus on forestry

Timo Ylänen customers and the forestry business, as well as to improve alignment and management of these product lines and to enhance Deere Forestry’s worldwide position. After graduating with MSc degrees in Forestry and Economics from the University of Helsinki and the Helsinki School of Economics and Business Administration, Ylänen has held various positions within the forestry industry, including roles with increasing responsibility at Timberjack, Deere & Company, and Waratah between 1994 and 2006. In 2007, Ylänen was hired by Komatsu Forest where he advanced from the position of Managing Director of Finnish Operations to become the Executive Vice President with global responsibility for Komatsu Forest’s sales and marketing.

Canada’s boreal, an equal to the Amazon Scientists have identified the 485 Mha Canadian boreal forest as the largest intact forest and wetland ecosystem remaining on earth. Rivalling the Amazon in size and ecological importance, Canada’s boreal supports the world's most extensive network of pure lakes, rivers and wetlands and captures and stores twice as much carbon as tropical forests. It teems with wildlife – including billions of migratory songbirds, 10s of millions of ducks and geese, and millions of caribou. The Canadian boreal is an irreplaceable global treasure. But, the boreal is under growing pressure. Recent studies have shown that globally, boreal forests are being lost faster than any other

ecosystem, largely due to logging, mining and oil and gas development. To date, Environmental trust, Pew, along with

The dark green strip of forest that runs from the west to east coasts across Canada and parts of Alaska is the massive and endangered boreal forest – a rival to the Amazon in size and environmental wealth

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its Canadian partners have worked to secure the protection of 75 Mha as parks, refuges and other nature reserves – about a third the amount scientists recognise as necessary to sustain the ecosystem over time. Bold new conservation measures have come from Ontario and Quebec and other provincial governments, First Nations and federal ministries. Most recently, Pew and its partners engaged the forest products industry in what could become the largest forest conservation plan in history. The trends bode well, promising to eventually make Canada's boreal the most protected forest on earth.

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SAWPOINTS

Bioenergy to benefit in Aussie partnership

ew Forests and the Clean Energy Finance Corporation have executed a collaboration agreement to finance new bioenergy and biofuel developments. The investments could include combined heat and power projects or renewable fuels projects featuring biodiesel or syngas associated with forestry investments in regional Australia. New Forests has invested in extensive forestry plantations in Australia, and the agreement may support establishment of new domestic markets for hardwood and softwood timber as well as traditional forestry and sawmill waste products. Under the collaboration agreement, New Forests will seek to develop commercially-oriented investment opportunities in renewable energy that complement regional forest sectors. “This is an opportunity to diversify Australian markets for timber, turn waste material into energy, and create new jobs and investment in rural Australia,” New Forests Managing Director David Brand said. “We see biomass based energy and liquid fuels as an area of substantial potential for growth, and an opportunity that could rival the size of traditional timber markets in the next 10 or 20 years.” CEFC CEO Oliver Yates described the deal as “an excellent demonstration” of the CEFC’s

ability to partner with the forestry industry in bioenergy developments “that will fulfil the potential for the industry to convert its waste products into a valuable renewable energy source”. “Investment in bioenergy can help reduce carbon emissions, lessen the reliance on traditional electricity and has the potential to boost productivity through reduced energy and operating costs,” he said. Bioenergy presently provides 0.9% of Australia’s electricity generation, but the Clean Energy Council estimates that this has the potential to increase six-fold by 2020 with the right support in place. “Linking Australia’s very significant forestry resources and skills and enhancing these through new clean energy technologies utilising cellulosic biomass will build a new industry of national value”, Mr Yates added. New Forests’ investments already include 375,000 ha of land and timber plantation assets in Queensland, New South Wales, Victoria, South Australia, Tasmania, and Western Australia and Timberlink Australia, with two softwood sawmills located in Tasmania and South Australia. Many of these plantations were established under managed investment schemes and now need concerted effort to

develop markets and infrastructure. “Market development is a key part of the work that needs to be done to reposition Australia’s plantation forestry sector for the future,” Brand said. “As an Australian business we seek to achieve excellent returns for investors, and innovation is a key part of that work.” The collaboration agreement is open to any projects brought forward by New Forests that meet the CEFC investment criteria. New Forests has identified a bioenergy plant in the Green Triangle alongside the Tarpeena sawmill as an immediate priority, as well as an assessment of the potential to use hardwood plantations for bioenergy and biofuel production at other locations.

Cat teams with SATCO on attachments deal Caterpillar Forest Products and SATCO have signed an agreement that gives Caterpillar the rights to sell and support SATCO harvesting attachments and parts worldwide. Caterpillar is the exclusive distributor everywhere except Australia, New Zealand and Brazil, where SATCO products will be offered both through SATCO's distributors and select Cat dealers. Headquartered in New Zealand, SATCO designs and manufactures a wide range of forestry attachments. “With this alliance, we can offer a full line of processing and directional felling heads for our FMs, track feller bunchers and the 501HD harvester,” Mike Duncan, Caterpillar Forest Products Industry Manager, said. “Cat dealers will offer a package fully supported by Caterpillar.” Products will continue to carry

the SATCO brand name. Built to handle the rugged logging conditions in New Zealand and Australia, the beefy heads are constructed using high-grade materials. Hoses from the carrier to the head are routed through the linkage and are not exposed. This protects the hoses from damage and prevents them from overbending causing premature failure. The line includes seven processing heads and two directional felling heads. The processing heads range from a weight of 1,190 kg (2,618 lb) with a maximum cutting diameter of 635 mm (25 in) to 3,850 kg (8,500 lb) with a cutting diameter of 800 mm (32 in). The felling heads are continuous rotation with optimal single stem felling ranges of 305508 mm (12-20 in) and 457-762 mm (18-30 in).

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SATCO also offers debarking configurations for its products, in addition to a specifically designed debarking processor head. All heads are designed to be matched with Cat Forestry Machines (FMs), track feller bunchers and the Cat 501HD harvester. The computer system in the processing heads is simple and easy to use. Main valves are rated at 420 bar (6,100 PSI) and can easily handle carrier pressures. Roller arm pins are 80 mm (3+ in). The heavy duty 3/4 in main saw

system features a 45 cc saw motor and large diameter bearing for smooth cross cutting and felling of large diameter trees. The directional felling heads are fully hydraulic with no electronics and have the same structural beefiness of the SATCO processing heads. Both heads can be used for shovel logging. One of the heads, the SAT420, can also be used to load trucks. Simple and strong, these heads are low maintenance and an economical first step up from manual felling.

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SAWPOINTS

New Micro Chip drum option available for select Bandit Whole Tree Chippers A specialized micro-chip drum from Bandit Industries is now available for select Bandit whole tree chippers.

he new drum design features double the knives found on a standard drum, delivering twice the cuts per rotation to produce wood chips as small as 3/16” in size. The micro-chip drum can also be easily converted to a normal chipping configuration for standard sized chips, allowing users to conveniently produce several different chip sizes to serve multiple markets. “Bandit chippers are already known for producing a great chip, but with biomass markets expanding rapidly around the world, we knew it was time to take an extra step for our customers,” said Bandit Industries President Jerry Morey. “Chip size certainly matters, but it usually comes at a cost of machine efficiency and performance. We set out to build a chipper that could make the best micro-chip on the market without giving up the performance people

expect from Bandit. And that’s exactly what we have with our new micro-chip drum.” The drum works in conjunction with Bandit’s flow control option for the feed system, which finetunes the feed rate of the machine to achieve minimum chip size with maximum production and fuel efficiency. A new chip breaker system further enhances chip quality, serving to screen and break down oversize material exiting the drum. The end result is a specifically sized micro-chip that is unmatched in consistency. Chip throwing power is unaffected by the design changes. The Bandit micro-chip drum and breaker system allow chips to exit the machine at high velocities without the need for a separate blower or chip accelerator. The combination of aggressive feed systems, smooth chipping and strong chip throwing adds to the

overall efficiency of Bandit’s whole tree chippers using the drum. Compared to similar machines producing micro-chips, Bandit whole tree chippers are averaging 33 percent better on fuel economy based on testing and customer feedback. “Customers using our micro-chip drum are consistently telling us just how hard the machine throws the chips, just like our standard whole tree chippers,” said Morey. “They are also reporting fuel consumption rates of roughly three tons per gallon depending on the

material, and throwing 40 to 50 loads per a set of knives isn’t a problem. We’re very pleased with the responses we’ve received on the micro-chip drum. It’s the ideal setup to serve any fuel wood market anywhere in the world.” The drum is an available option for the Model 2590, Model 3090 and Model 3590 whole tree chippers. The drum and accompanying systems can also be retrofitted to existing Bandit whole tree chippers.

EU stalls forestry framework

November 6-8 2013

European forest related organisations are concerned about the European Commission’s delay in publishing the new EU Forest Strategy. The European Commission is postponing publication of the strategy, even though forests represent 40% of land use in Europe. “The clock is ticking,” Juha Hakkarainen, Chairman of the EU Advisory Group on Forestry and Cork said. “Further delay in proposing a coherent approach on Europe’s forests can only lead to more fragmented and possibly contradictory decisions.” It seems that the European Commission is hesitant in embracing a consistent and coherent approach on forests and forestry. The Advisory Group on Forestry and Cork, as well as Member States representatives (via the Standing Forestry Committee), recently urged the Commission to overcome the last obstacles and to release the strategy so that it can be examined by the European Parliament and the EU Council. Still, no action had been taken at

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time of writing. The expected European Commission Communication on a new EU Forest Strategy would update and replace the existing Forestry Strategy that dates back to 1998. It would take into account the new challenges for forests and forestry policy in reference to climate change, renewable energy, biodiversity, resource efficiency and the green economy and establish a coherent framework with other policy areas. Moreover, the new Strategy would be based on the concept of sustainable forest management and the multifunctional role of forests.

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SAWPOINTS

Weyerhaeuser Company maintains sustainable growth objectives Weyerhaeuser Company now owns or manages approximately 20.5 million acres of forestland in the U.S. and Canada including acquisition of Longview Timber’s approximately 645,000 acres of forestland in Washington state and Oregon in July, making the company one of North America’s and the world’s largest private sustainable forestry operations. “

eyerhaeuser is dedicated to industry leadership in forest stewardship and sustainability, and we will continue that leadership as we bring the recently acquired Longview Timber operations into our portfolio,” said Tom Gideon, Weyerhaeuser’s executive vice president of Timberlands. “All of Weyerhaeuser’s North American forests will continue to be certified to the Sustainable Forestry Initiative® standard, which ensures that our forest management practices meet a broad spectrum of social, economic and environmental requirements.” With more than 240 million acres within its purview, the Sustainable Forestry Initiative is the largest forest certification standard in the world. Certification criteria are established by a diverse group of community organizations, environmental groups, industry, academia and government agencies. “By successfully achieving independent, third-party certification of its lands to the SFI standard, Weyerhaeuser has demonstrated a

strong commitment to responsible forestry and to the communities that depend on a variety of forest benefits,” said Kathy Abusow, president and CEO of the Sustainable Forestry Initiative. To become SFI certified, auditors assess compliance in dozens of factors key to responsible, renewable forest management, including demonstrated performance in forest productivity and health, sustainable harvesting, protection of water resources, promotion of biodiversity and fish and wildlife habitat, protection of at-risk species, legal compliance, training, ongoing research and continuous improvement, and more. “Customers expect accountable forest stewardship, and consumers want to make informed buying decisions,” Gideon said. “SFI certification, along with complementary programs such as the American Tree Farm System for family forest owners, provides assurance that Weyerhaeuser wood is sourced responsibly.” These market forces are spurring significant growth in forest certification. For example, the

acreage certified by the Sustainable Forestry Initiative has grown 71% since 2007. Despite such growth, however, global forest certification stands at about 10%. In contrast, 100% of Weyerhaeuser’s forests worldwide are certified. “We achieved 100% certification in our North American operations several years ago, and this year we also achieved full certification for our forests in Uruguay,” Gideon said. “It’s a standard we’ve set for all of our operations.”

New Chief Forester at Western Forest Products Inc. Western Forest Products Inc. has appointed Shannon Janzen as Chief Forester. Previously Manager, Strategic Planning, Ms. Janzen is a Registered Professional Forester and clearly demonstrates the leadership qualities required for the role of Chief Forester. She brings over 10 years' experience in developing and implementing land use policies and practices. Ms. Janzen also has a proven track record of building strategic relationships and partnerships with First Nations, Environmental groups and various levels of Government on the coast of British Columbia. In her new role, Ms. Janzen is accountable for developing and implementing economically viable and environmentally responsible strategies and solutions associated with business investments on crown lands to advance the Company's strategy. She will also ensure the Company continues to demonstrate sustainability across its operations and through the safe management of its forest tenures. "I am very pleased that Shannon has accepted the

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role of Chief Forester," said Don Demens, President and CEO. "She has been instrumental in helping us establish positive business relationships and joint ventures with First Nations and her knowledge of our industry has been critical in defining our long-term strategy at Western. I am confident her leadership will continue to strengthen Western's position as a globally competitive forest products business." Western Forest Products is an integrated Canadian forest products company and the largest coastal British Columbia woodland operator and lumber producer with an annual available harvest of approximately 6.4 million cubic metres of timber, of which approximately 6.2 million cubic metres is from Crown lands and lumber capacity in excess of 1.1 billion board feet from eight sawmills and two remanufacturing plants. Principal activities conducted by the Company include timber harvesting, reforestation, sawmilling logs into lumber and wood chips and value-added remanufacturing.

Shannon Janzen, Chief Forester Western Forest Products Inc

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WORLD MARKETS

American pellet exports hit record levels North American wood pellet exports reached a new record of more than 1 Mt in the first quarter, according to the North American Wood Fiber Review. There has been steady growth in shipments from both the US and Canada the past few years, mainly as a result of the continued increase in demand for pellets in the United Kingdom

ellet exports from the two primary pellet-producing regions on the North American continent – the US South and British Columbia – showed no signs of slowing in early 2013, with the rate of growth likely to accelerate in the second half of the year. In the US South, pellet export volumes to Europe resumed their double-digit growth after a brief pause in the fourth quarter last year. Export volumes, based on information from industry sources as well as trade data in Europe and North America, showed exports in excess of 1.7 Mt in 2012, as reported in the North American Wood Fiber

Review (www.woodprices.com). Canadian exports also rose in 2012 to 1.5 Mt, but this increase was less than that seen in the US. During the March quarter, total pellet exports from North America reached a new record of more than 1 Mt for the quarter. This can be compared to the annual shipments of 750,000 t just four years ago. The United Kingdom continues to strengthen its claim as the primary destination for North American pellets with over twothirds of the export volume from the US and Canada going to the UK in the first term. The story of Drax’s plans for its

large power plant conversion from coal to biomass in Selby, England, continues to make news across North America. Earlier in the spring, Drax Biomass International (DBi), a US-based subsidiary to Drax Power, announced that it will develop, construct and manage two pellet plants, a port storage and a loading facility in the US South, which will be sending pellets to fuel the company’s UK facility. Also, in Eastern Canada, pellet producer Rentech announced an off-take agreement with Drax Biomass, which will result in new investment in ports to increase pellet-loading capacity, and in rail

transportation, along with the construction and operation of two pellet facilities themselves. The increase in pellet production in Western Canada has pushed sawdust prices upward the past few years, with 2013 prices being about 15% higher than they were in 2010, as reported in the NAWFR. In the US South, where smaller logs from thinnings and treetops are commonly used for pellet manufacturing, there has not yet been any region-wide upward price pressure as a result of the new wood-consuming sector in the region.

Sawmills to spring back to life Pre-tax profits in Canada’s wood products industry are expected to more than double this year and reach an eight-year high, according to The Conference Board of Canada’s Spring 2013 outlook “Canada’s wood products industry is cashing in on the recovery in the US housing market and strong Chinese demand for wood products,” said Lin Ai, an inhouse economist. Highlights include; • Price improvements and higher production mean that industry revenues will rise to a six-year high, reaching $C24 billion in 2013 • Production increases will drive costs higher, but revenue gains will be more than sufficient to cover them • The industry continues to reap the benefits of cost-cutting measures undertaken even before the 2008-09 economic recession. The end result is that

2013 will be the fourth consecutive year of profitability. The positive news is tempered by weakness in the domestic housing market, but the rebound in the US housing market and robust exports to China will more than offset the slackening demand at home. Industry production will continue to rise each year through 2017. However, the pace of growth will slow down in the outer years of the forecast, as production will be constrained by lower timber supply – a result of the mountain pine beetle infestation in British Columbia. Some 6,000 new workers are expected to be added to payrolls in 2013. However, producers are

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facing a skilled-worker shortage, which will pose a major challenge for the industry going forward. In contrast to the surging outlook for wood products, this year is shaping up to be a disappointing one for Canada’s Paper Products Industry. Revenues will drop slightly due to weaker production, which has also resulted in declines in both material inputs and employment. Although costs should be lower this year, it will not be enough to keep the industry in the black. The industry is expected to record a pre-tax loss of $213 million in 2013. The industry is expected to turn a pre-tax profit 2014, but profit margins will remain thin over the next four years.

Bright spots in the paper industry outlook include rising demand from emerging markets and growth in certain segments of the industry, such as sanitary paper and other higher valueadded paper products, all of which are helping to offset declining demand for newsprint.

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WORLD MARKETS

Deere records tumble despite construction, forestry struggle Net income for Deere & Company for its third quarter was $996.5 million, or $2.56/sh compared to $788 million for the same period last year. For the first nine months of the year, the group netted an impressive $2.73 billion up from $2.377 billion last year

Worldwide net sales and revenues increased 4% to more than $10 billion for the third quarter and rose 8% for the nine months. Net sales of the equipment operations were $9.32 billion for the quarter and $26.37 billion for nine months, compared with $8.93 billion and $24.45 billion for the same periods last year. “John Deere is well on the road to another year of impressive performance after reporting record third-quarter results,” Chairman and Chief Executive Samuel Allen said. “Sales and income for the

period were higher than in any prior third quarter. “Deere’s success is a reflection of considerable strength in the farm sector, especially in North and South America. We also are making further progress executing our wide-ranging operating and marketing plans, which call for expanding our global market presence while keeping a close watch on costs and assets.” For the Construction and forestry division, however, things were less bullish. Sales decreased 11% for the quarter and 8% for

nine months mainly as a result of lower shipment volumes. Operating profit was $107 million for the quarter and $259 million for nine months, compared with $113 million and $356 million last year. The quarterly operating-profit decline was primarily because of decreased shipment volumes. Reduced shipment volumes also had an impact on the nine month figures, though increases in production costs, an unfavourable product mix and higher selling, administrative and general

expenses, also caused problems. Price realisation and lower research and development expenses largely offset the negative influences. Deere’s worldwide sales of construction and forestry equipment are forecast to decrease by about 8% for 2013. The decline mostly reflects a cautious outlook for US economic growth. Global forestry sales are expected to be higher for the year as improved US demand more than offsets weakness in European markets.

Dragon regains its appetite After a decline in importation of logs and lumber into China in 2012 and early 2013, the country came roaring back to life in the second quarter with the import value increasing by more than 30% yearover-year, as reported in the Wood Resource Quarterly. The total value of imported softwood logs and lumber was more than $2.2 billion in the June quarter, an increase of almost $600 million from the previous quarter. The higher demand for wood products comes as house-building activities have increased in the

first half of 2013 as compared to the same period in 2012. Yearover-year, investments were up 13% in residential buildings, and 23% in commercial buildings, according to recently published official Chinese statistics. During the past few years, importation of lumber has grown at a faster pace than that of log imports with the share of lumber of the total import value having gone up from 35% in 2010 to 42% in the June term. The import volumes have almost tripled in four years with Russia and Canada having been the two major

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suppliers of softwood lumber, together accounting for almost 80% of all lumber imported to China over the period. European sawmills have not had a major presence in the Chinese wood market but this is changing. In June of this year, European shipments accounted for over 8% of the total lumber imports to China. It can be expected that more containers of lumber will find their way from Europe to China in the coming years. The Chinese log import market, which once was completely dominated by Russia, has evolved the past

four years to a more diversified group of supplying countries, as reported in the Wood Resource Quarterly. New Zealand has become the largest softwood log supplier to China, Russia’s presence has diminished, and the US and Canada currently supply 25% of all logs imported to China. Russia’s log exports to China are likely to continue to decline, but there will likely be opportunities for Russian sawmills to increase their shipments in the future.

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WORLD MARKETS

Canfor reports second quarter 2013 results

anfor Corporation reported net income attributable to shareholders (“shareholder net income”) of $110.3 million, or $0.77/sh, for the second quarter of 2013, compared to $61.9 million, or $0.43/sh, for the first quarter of 2013 and $2.6 million, or $0.02/sh, for the second quarter of 2012. For the six months ended June 30, 2013, the Company’s shareholder net income was

$172.2 million, or $1.21/sh, compared to a shareholder net loss of $15.4 million, or $0.1/sh, reported for the first half of 2012. The shareholder net income for the second quarter of 2013 included various items affecting comparability with prior periods, which had an overall net positive impact on the Company’s results of $22.6 million, or $0.16 per share. After adjusting for such items, the

Company’s adjusted shareholder net income for the second quarter of 2013 was $87.7 million, or $0.61/sh, up $17.4 million, or $0.12/sh, from an adjusted shareholder net income of $70.3 million, or $0.49/sh, for the first quarter of 2013. Adjusted shareholder net income for the second quarter of 2012 was $9.2 million, or $0.07/sh. The Company reported

operating income of $128.2 million for the second quarter of 2013, compared to operating income of $100 million for the first quarter. The positive variance reflected improved results in the lumber segment mostly as a result of increased shipments and, to a lesser extent, lower manufacturing costs.

Norbord credits OSB prices and housing recovery for upsurge in earnings Norbord Inc. has reported EBITDA of $102 million in the second quarter of 2013, compared to $31 million in the same quarter last year and $111 million in the first quarter of 2013. North American operations generated EBITDA of $92 million in the quarter versus $26 million last year and $106 million in the prior quarter. European operations generated EBITDA of $12 million in the quarter versus $9 million last year and $10 million in the prior quarter.

Norbord recorded $53 million of earnings in the second quarter of 2013 compared to $6 million in the same quarter last year and $67 million in the prior quarter. “In North America, we experienced a significant OSB price correction in the second quarter,” Barrie Shineton, President and CEO said. “Although prices were expected to adjust after reaching record levels in the first quarter, I was surprised by the degree of the correction. OSB prices are now

recovering and I believe this trend will continue as the fundamentals supporting US new home construction remain very strong.” “In Europe, panel demand and prices, particularly for OSB and particleboard, improved again this quarter and are reflected in our financial results. And, we are beginning to see early signs of a fundamental turnaround in UK housing. This is encouraging as the UK continues to be Norbord’s most important European market.”

June year-to-date US housing starts and permits were both 24% higher than the same period last year. Single family starts were 20% better. Other key housing metrics, including home prices, existing home sales and the inventory of foreclosed homes, continued to improve. The consensus forecast of US housing economists remains at 1.0 million starts for 2013, a 28% increase over last year.

AUGUST/SEPTEMBER 2013 | International Forest Industries 15

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WORLD MARKETS

Slowdown in paper and board consumption

EPI has released the latest European pulp and paper industry statistics, which give a clear picture of the performance of the industry in 2012 and do not make for pretty reading. These key statistics include data about production, consumption and the trade of pulp, paper and raw materials, as well as data concerning energy, environment, and social affairs. European pulp and paper production in 2012 continued to be affected by the economic slowdown that began in mid-2011. Notably, its

performance remains above other energyintensive sectors in Europe. The European paper industry is looking for a healthier supply and demand balance and is modernising its industrial base to remain competitive. The overall output performance of all CEPI member countries during 2012 was similar to that of other major traditional paper producing world regions, such as USA, Japan and South Korea. Only China and Brazil performed better. CEPI members produced 92.1 Mt of paper and board in 2012, which represents a decrease

of 1.6% over 2011. The pre-crisis production in 2008 totalled 97.9 Mt. Pulp production fell by 1% while the output of market pulp increased by 4.3%. Exports of paper and board outside Europe showed an increase by 5.3% whilst imports fell by 9.7% when compared with 2011. The overall consumption of paper and board in CEPI fell by 3.8% last year. In comparison the overall GDP in Europe decreased by 0.3% in 2012, but it will recover in 2014 with a 1.4% increase (source: Eurostat – EU27).

NZ Log Export Update New Zealand exports Prices have decreased in export destinations, which are pushing down prices at the wharf gate, though as expected this has been mitigated to some extent by the drop in the NZ dollar. Most prices this month have remained flat though export pruned prices have dropped considerably. Pruned exports are down $6/t on average, though the largest drop has come in the northern North Island where prices are down $10/t. The rest of the country has averaged drops of closer to $3/t. This is due to the sap stain issues logs have been having in ports in China, and has had more effect on at-wharf-gate returns as the demand is still high for pruned logs which is supporting the current in-market log prices. NZ had a very large month for log exports during May, exporting 1.4/mt, including over 1 million tonnes to China. This left NZ well on track to exceed the highest half year total ever for exports, despite including the typically slow January and February period. Exports this year so far are averaging just under 1.3/mt per month. May was a month of record exports from Tauranga, with 620,000t exported during the month. This was a large step up from the month previous. But over the last year, growth in Tauranga has not been as rapid as out of Whangarei, which had a 38% increase year on year for the year to May. China imported another very large amount of logs in May, slightly down on April’s record volume, but at just over 2.9 million m3 it has contributed to a huge first half of 2013 for log imports. 12.4 million m3 have been imported this year to May. NZ is now consistently the largest supplier of logs to China, and has a 36% market share, compared to Russia’s 30% and the Pacific North West with 23%. This is a 2% increase of market share for NZ, compared with a drop of 10% year-on-year for Russia’s market share. Investment in wood manufacturing within China has increased in May, and has been

relatively high through the start of 2013. For the first five months of the year, cumulative investment has been 32% higher than the start of 2012. Investment typically rises in the from April onwards and so while it has been a promising start the total investment is still around 30% lower than when log prices reached their peak in 2011. Exports to South Korea dropped back slightly in May, though are still close to the 200,000 million mark. Though the South Korean economy has been slowing and there have been issues around slow building and bad weather, it is proving to be a very steady market. The start

to exports this year has been 9% higher than the five year average. While exports to South Korea tend to be cheaper industrial K – grade logs, compared to the larger A-grade logs sent to China, the strong prices in China have caused the Korean market to lift as well so that average export prices are 17% above year ago levels as at May. Exports to India have been much steadier this year than in 2012 when there were large month to month fluctuations. The Indian economy is stagnating, while inflation is growing while productivity wanes. Source: www.nzxagri.co.nz/agrifax

Significant growth seen for wood plastic composites Wood and other natural fibres have been used in composites for many years. Recently there has been a resurgence of interest, particularly development of the wood-plastic composites industry and nanocellulose composites reports Plasemart. The global market for applications of wood-plastic composites (WPCs), cellulosic plastics, plastic lumber and natural fibre composites was estimated at about 2.4 million metric tons in 2011. By 2016, it is estimated at nearly 4.6 million metric tons and rising at a robust compound annual growth rate (CAGR) of 13.8%, as per BCC Research. The market for building products is expected to experience the highest growth, at a compound annual growth rate (CAGR) of 12.4% during the 5-year period from 2011 to 2016. This sector is expected to be worth 1.7 mt in 2011 and nearly 3.2 mt in 2016. The market for automotive applications is estimated at 350,000 metric tons in 2011 and is expected to increase at 17.1% compound annual growth rate (CAGR) to reach nearly 8,00,000 mt in 2016. US demand for wood-plastic composite and plastic lumber is projected to advance over 13% pa to $5.4 billion in 2015. Advances will be driven by a rebound in construction expenditures from a depressed 2010 base. Further growth will be boosted by

16 International Forest Industries | AUGUST/SEPTEMBER 2013

increasing consumer demand for building products made from composite and plastic lumber, instead of more traditional materials, such as natural wood. Wood-plastic composite lumber will register more rapid gains than plastic lumber, advancing over 16% pa to US$2.5 billion in 2015. Gains will be driven by ongoing consumer interest in the material as a substitute for natural wood products in such applications as decking and fencing. Moreover, because wood-plastic composite lumber incorporates recycled materials, it is seen as an environmentally friendly building material. As per Research and Markets, firm growth is forecast for wood plastics composites in Europe despite financial woes. From a slow start around 40 years ago, in the automotive sector, European production of wood plastics composites has both diversified in its applications and grown rapidly over the last five years to reach 193,000 tons by 2010. Another report forecasts continuing growth to almost 360,000 t by 2015, which represents – average annual growth of 13%, but nevertheless a slowing in growth compared with the 2005-10 period, as a result of the continuing difficulties in European economies. Source: Plasemart.com

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WORLD MARKETS

Ilim Group inaugurates the world’s largest fiberline built under the big Bratsk project

lim Group recently inaugurated its new pulp mill in Bratsk (Irkutsk Oblast), the largest investment project completed in the Russian pulp and paper industry over the last 30 years and the world's largest fiberline. A symbolic “key turning” ceremony was attended by Dmitry Medvedev, Russian Prime Minister, Zakhar Smushkin, Chairman of the Board of Directors of Ilim Group, John Faraci, Chairman and Chief Executive Officer of International Paper, and Sergey Eroschenko, Governor of the Irkutsk Oblast. Total investments in the Big Bratsk project exceeded $800 million. Annual capacity of the new fiberline after ramp-up will reach 720,000 t of bleached softwood market pulp, with the total annual pulp and paper products output of the Bratsk Mill of OJSC Ilim Group exceeding 1 million tons per year. This successfully completed project will make the Bratsk Mill more efficient and more environmentally friendly. In addition to the construction of a new fiberline, the project involved the upgrade of the infrastructure, including construction of a new recovery boiler, new woodyard, new chemicals preparation plant, etc. The Mill is now fitted with the cutting edge equipment supplied by the world’s leading manufacturers. In his speech Dmitry Medvedev congratulated

the participants of the inauguration ceremony with a start up of the new fiberline. “This is an important and long-awaited event. This industry has not seen such large investments over a long time, and this is a remarkable milestone for the entire industry,” said the Prime Minister. “The Big Bratsk project is a good example of wellcoordinated efforts of business community and regional and federal authorities.” “We have completed an ambitious project. Rebuild of the Bratsk Mill will give a new impetus

to the development of the mill, the city and the region as a whole. New high-qualified jobs have been created together with new opportunities for implementation of social programs, said Zakhar Smushkin. “In the immediate future we will be learning to ramp up the new fiberline. I would like thank all those who have been involved in the implementation of the project: our mill employees, our contractors, and all vendors who have worked with us.”

Canadian sawmills record highest level of sales since 2007 According to the Canada's National Statistical Agency, total sales in the wood product industry were up 19.7% over the 12-month period from June 2012 to May 2013 compared with the same period one year earlier. By comparison, total manufacturing sales in Canada, excluding wood products, decreased 1.1% over the same period. Wood product manufacturing was one of only eight industries where sales increased from June 2012 to May 2013, and represented both the largest dollar gain and largest percentage gain by industry. Sales in wood product manufacturing reached $22.7 billion from June 2012 to May 2013, their highest point since 2007/2008. The rise in exports was largely attributable to growth in the US housing market. Data published by the US Census Bureau report that unadjusted housing units started in the United States reached 863,600 units from June 2012 to May 2013, up 28.9% compared with the same period a year earlier. The IPPI indicates that wood prices in sawmills and wood preservation industry have risen 10.5% over this period as a result of increased demand. AUGUST/SEPTEMBER 2013 | International Forest Industries 17

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WORLD MARKETS

Forestry funds target Australasia Two forestry funds dedicated to Australiasia have been armed with $AU740 million that will be used to buy up sustainable plantation investments

ew Forests closed out the New Forests Tropical Asia Forest Fund (TAFF) in July with a total of $AU170 million in capital commitments, which will be invested in sustainable plantation forestry investments in Southeast Asia, with a primary focus on Malaysia, Indonesia, and Vietnam. By the time the fund closed, New Forests had also completed the fund’s first investment, the acquisition of a majority interest in the Hijauan group, which includes the wholly-owned Hijauan Bengkoka Plantations and a 50% shareholding in Acacia Forest Industries. Together, these two companies are responsible for management, harvest, and future rotations of an Acacia mangium plantation in northern Sabah, Malaysia. The plantation area currently includes approximately 11,000 ha of acacia plantation, producing sawlogs and pulpwood for domestic and regional export markets. “The Hijauan plantation estate is an excellent first exposure for TAFF into the high-growth timber markets of Southeast Asia,” New Forests Managing Director David Brand said. “The asset is a strong

November 6-8 2013

fit for TAFF as it will generate immediate cash flow from mature timber and have exposure to export markets offering a premium for the asset’s FSC-certified timber. The investment also provides opportunities for TAFF to make management, governance, technical, and operational improvements that will increase the value of the estate.” As timber supply from natural forests in Southeast Asia declines, there is an increasing need for investment in high quality, sustainably managed plantation forests. TAFF is the first private investment vehicle dedicated to sustainable plantation timber production in Southeast Asia using long-term, institutional capital. TAFF will establish a portfolio of assets producing high value sawlogs and veneer logs. The fund’s investments are overseen by New Forests Asia (Singapore) and managed by coportfolio managers Darius Sarshar and Paul Speed, supported by a team of specialist forestry and investment professionals. “TAFF will participate in the development of Southeast Asia’s plantation forest industry,” said New Forests Asia Director Paul Speed. “The fund offers the scale and resources to provide our clients with a regional forestry portfolio diversified across species, countries, and market exposures within Asia. Forestry investment in emerging markets requires the disciplined approach of traditional timberland investment but also demands a high standard for managing environmental, social, and governance aspects of investments.” New Forests is a signatory to the UN-backed Principles for Responsible Investment and operates a corporate social and environmental management

18 International Forest Industries | AUGUST/SEPTEMBER 2013

Dr. David Brand Managing Director

Darius Sarshar Director, New Forests Asia

system. These commitments support New Forests’ risk management systems using thirdparty forest certification and performance standards. “A sustainable investment approach is necessary in Southeast Asia, in order to balance a growing wood demand with positive community relations and environmental stewardship,” remarked fellow New Forests Asia Direector, Darius Sarshar. A few days before TAFF was closed, New Forests closed an even bigger fund worth $AU570 million targeting Australian and New Zealand investments called the Australia New Zealand Forest Fund 2 (ANZFF2). The fund will target hardwood and softwood timber plantation investments. ANZFF2 is New Forests’ second timberland fund investing in the forest sectors of Australia and New Zealand. The company’s first such fund, ANZFF, closed in October 2010 with $AU490 million in commitments and is now fully invested. Including co-investments with ANZFF, New Forests has invested more than $AU1 billion in the regional forestry sector for its clients over the past three years. ANZFF2 offers qualified investors exposure to a region with strong forest sector fundamentals, including a robust operating environment, low technical risk, established domestic and export timber markets, and nearly 4 Mha of existing timber plantation assets across the two countries. Australia and New Zealand have seen an increase in institutional ownership

Dave Shelton Director, Investment Programs, AustraliaNew Zealand

of forests as the industry restructures, reducing corporate and government ownership. New Forests has estimated that over the next five years, approximately 25% of global institutional timberland investment transactions will occur in Australia and New Zealand. “Australia and New Zealand offer attractive but distinct timberland investment opportunities, with some premier assets likely to come to market over the next two to three years,” Brand said. “New Forests has demonstrated an ability to invest successfully in our region. We offer our clients specialist expertise and local knowledge in a region exposed to demand growth from both domestic and Asian export markets.” New Forests’ investment business is led by Brand and Head of Funds Management James Davies. The ANZFF2 portfolio will be managed from the company’s Sydney headquarters with Director of Investment Programs David Shelton leading acquisitions and Director of Operations Keith Lamb leading asset management. Since New Forests’ establishment in 2005, Lamb and Shelton have undertaken numerous investments in Australia and New Zealand including both softwood and hardwood plantations and the Timberlink softwood timber processing, sales and distribution business.

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WORLD MARKETS

Plum Creek Timber announces second quarter 2013 earnings Plum Creek Timber Company, Inc. announced second quarter earnings of $46 million, or $0.28/sh, on revenues of $303 million. Earnings for the second quarter of 2012 were $36 million, or $0.22/sh, on revenues of $294 million.

arnings for the first six months of 2013 improved $37 million compared to the same period of 2012. Earnings were $102 million, or $0.62/sh, on revenues of $643 million. Earnings for the first six months of 2012 were $65 million, or $0.40/sh, on revenues of $631 million. Adjusted EBITDA, a non-GAAP measure of operating performance, for the first six months of 2013 was $232 million, similar to the $234 million in the same period of 2012. Plum Creek Timber ended the quarter with $355 million in cash and cash equivalents. A reconciliation of adjusted EBITDA to net income and cash flow from operations is provided as an attachment to this release. “Each of our business segments performed well during the second quarter,” said Rick Holley, chief executive officer. “We are experiencing fundamental demand improvement and better pricing;

although, we remain in the very early stages of the housing recovery. As the industry adjusts to this change in the demand environment, regional markets we serve are recovering at different rates. This is when our unmatched, geographic diversity gives us tremendous operating flexibility. It allows us to act and capitalize on strong local markets, growing earnings and cash flow while maximizing the long-term value of our asset base.” The Northern Resources segment reported operating profit of $8 million during the second quarter, an increase of $4 million compared to the second quarter of 2012. Average sawlog prices increased $8 t, or 11%, compared to second quarter 2012 levels on improved demand from both domestic and export customers. Pulpwood prices were similar to the prices realized during the second quarter of 2012. As

planned, total Northern segment volumes decreased approximately 160,000 tons, or 17%, from the second quarter harvest of 2012. Most of the reduction in harvest volume consisted of lower-margin pulpwood. Operating profit in the Southern Resources segment was $23 million, up $1 million from the $22 million reported for second quarter of 2012. Higher prices for both sawlogs and pulpwood offset lower harvest volumes. Sawlog prices increased $1 t, or 5 percent, and pulpwood prices increased $1 t, or 10 %, compared to the second quarter of 2012. Overall the Southern harvest declined about 500,000 tons, or 14%, compared to the second quarter of 2012. While our full-year 2013 Southern harvest is planned to be similar to 2012’s harvest level, the 2013 harvest is weighted to the second half of the year to capture the expected improvement in log prices.

The Manufacturing segment reported operating income of $14 million, a $5 million improvement over the second quarter of 2012. Strong demand and pricing continued to benefit each of the company’s manufactured product lines. Plywood prices increased 13% compared to the second quarter of 2012 on strong industrial demand. Plywood sales volume declined 6% compared to the same period of 2012 due to reduced log availability. MDF prices were up 8 % compared to second quarter 2012 while sales volume grew 15%. In April of this year, the company re-opened its Evergreen lumber mill, boosting lumber sales volume by 21 % compared to the second quarter of 2012. Average lumber prices declined approximately 1% as the product mix shifted to include lower-priced stud lumber from the re-opened mill.

Weyerhaeuser pays $2.65 billion for Oregon, Washington timberlands Timber giant Weyerhaeuser Co. has acquired Longview Timber and its 645,000 acres of timberland holdings in Oregon and Washington for $2.65 billion. The deal closed on July 23rd. Brookfield Asset Management Inc., the Toronto-based seller, is also selling its Longview Fibre Paper and Packaging Corp. to KapStone Paper and Packaging Corp. for just over $1 billion. The company operates a Longview, Wash., paper mill and seven paperand-cardboard in the Pacific Northwest. Brookfield had acquired the properties for $2.15 billion in 2007. The timberland deal, announced Sunday and expected to close in July, would be the third-largest forestry acquisition in North American history, Bloomberg News reported. It increases the Pacific Northwest holdings of Federal Way,

Wash.,-based Weyerhaeuser by one-third, the company said. “This is a one-of-a-kind acquisition,” Tom Gideon, Weyerhaeuser's vice president for timberland, said in a conference call for investors and analysts. “It is highly unlikely that the opportunity to acquire high-value and high-quality timberland of this magnitude in the Pacific Northwest will reappear again.” The eye-popping purchase price includes debt Weyerhaeuser will take on. The company said it will finance the deal by selling $2.45 billion in long-term debt and equity, and it announced it would offer 10 million mandatory convertible preference shares at $50 a share. The shares will automatically convert to a variable number of common shares on July 1, 2016. Upon completing the

acquisition, Weyerhaeuser said it would increase its quarterly dividend to 22 cents a share, up from 20. The Portland-based law firm Stoel Rives represented Brookfield in acquiring the timberland and paper operation, then a single company, and restructuring and selling both. “We don't see transactions of this size in Oregon and Washington all that frequently,” said Greg D. Corbin, head of the law firm's forest products initiative. “What this shows is a strong, healthy interest in timberland ownership which is tied to what we're seeing in the economic recovery, both in the housing market and domestic demand and overseas exports.” Weyerhaeuser said the deal will expand its reach in international markets. About 20 percent of its timberlands revenue comes from

sales to Japan, China and Korea, and Pacific Northwest timberlands are strategically located for export to Asia. The primarily older trees, mostly Douglas fir, will let Weyerhaeuser immediately start harvesting export-quality logs earlier that are large enough for use in Japanese post-and-beam house construction, and the distribution of tree age will allow for continuous harvesting. “While the total acreage is important, it is the location of these timberlands, along the West Coast and in particular west of the Cascade mountain range, that makes this so compelling,” Weyerhaeuser executive vice president Patty Bedient said in the conference call. The company also installed Doyle Simons, formerly chief executive of forest products company Temple-Inland, as CEO.

AUGUST/SEPTEMBER 2013 | International Forest Industries 19

SCANNING & OPTIMISATION

Scanning for blue skies

An installation of the Goldeneye-500

This year’s Scanning & Optimisation technology review could be the precursor to some true revelations for the sawmilling sector in the years to follow

t’s taken what has felt like an eternity, but finally things seem to be picking up for sawmillers. That’s what our contacts amongst the sawmill supplying community are telling us, anyway. It has been a long, slow crawl out of the mire for the sawn wood products industry in comparison to the logging sector but better times do now seem to have arrived. The recovery has been led of course by the US, where the crucial indicator, housing starts, has been on the improve and general economic data has prompted economists the world over to call the end to uncertainty and the return to some sort of normal growth, albeit at a muted rate. Across the ditch in Europe, things are not as bright but the volatility appears to have abated. The serious threat of Eurozone disaster is no longer at the head of national papers and, while the economic prospects of many nations remains subdued, the chances of more crisis has been largely removed. Giving more

20 International Forest Industries | AUGUST/SEPTEMBER 2013

credence to the sawmilling revival has been the continued relative strength of the Nordic economies, which are not only Europe’s best performing centres but are also those with the most significant forest industries. It is in this light that this year’s Scanning & Optimisation review must be viewed. This year there has not been a huge unveiling of industry-changing technology but suppliers have been busy. Most of the scanning improvements have centred on better vision and defect detection in the cant rather than on cost-effective products and services. Though sawmills are still keen to minimise their outlays, this demand for higher performing technologies is new. Suppliers have not spent as much as previous years on their product development but those that have survived have also not put away the cheque book altogether. Now that there is an uptick in the sector, this magazine would speculate that spending will increase – funded largely by the early stages of the current surge in orders – and there is

likely to be a whole new series of scanning and optimisation technology across these pages in the next five years. The upturn in the economy has had Lucidyne hopping to keep up with orders for its GradeScan lumber grading system and continuing its efforts to advance its technologies toward fully understanding the characteristics of wood fibre strength and appearance. Continued research is aimed at accuracy improvements in strength grading, partially from using a new 3D grain angle sensor. More success with identifying the best productioncapable configuration for its T3 decay sensor will finally get it out of the lab and into two Canadian mills this year. There are high expectations that the T3 addition to Tolko and Western Forest Products plants will also improve other areas of fibre analysis. Two specific challenges have been accurately measuring knots when they are covered with blue stain or when the knot head is the same colour

SCANNING & OPTIMISATION

This is truly a first in our industry and is one way to take advantage of the many possible combinations of lengths and grades available from automated grading – instead of being constrained by limited sorting capacity – Lucidyne

Colour picture of board with timber break

Tracheid image of the same board showing timber break

as the surrounding fibre. “Improvements here will help reduce grading errors and in turn generate more value for owners of this technology,” Lucidyne said. One more technology leap takes another challenging defect off the list – ‘timber break’. This defect leaves the fibre fractured across the grain and makes a board very weak. It can regularly be found when a grader turns the board over by hand because there is sometimes enough damage to to be seen or damage can be ‘felt’ or ‘heard’ through vibrations. Automated turners reduce this opportunity. “It is easy to find it with a continuous bending machine, but only mills that strength grade for MSR or MEL products are likely to have that tool,” the supplier said. “Visual scanners are less effective than a grader since they do not ‘touch’ the board.” Lucidyne’s success came from an increase in its scan density. The defect is not easily seen when looking at the colour image here, but the high-definition view from the company’s tracheid sensor makes the defect much more obvious. This sensor takes advantage of the physics of softwood tracheid cells and light energy, sometimes referred to as the T1 effect, showing that the light traveling along the tracheid cells is disturbed by the sudden fracture perpendicular to the tracheid alignment.

Some of Lucidyne’s more recent installations have unique challenges, as each one is customised for its respective mill. Anthony Timberlands in Bearden, Arkansas, had experienced graderassisted geometric grading and was looking forward to stepping up to implementing full biological scanning. Four months after installation, Timberlands bought a second GradeScan scanner for the Malvern mill for installation at the end of this year. Idaho Forest Group recently took over a Potlatch mill in Lewiston, Idaho and completed the first phase of an automated grading project. Its first GradeScan was brought into production in the plant just this August, replacing a geometriconly system. After the remaining mechanical equipment is installed and the project completed at the end of August, its GradeScan will first scan boards, trim, and then direct them to either a tray sorter or bin sorter. The unique configuration of this system takes advantage of the scanner’s ability to grade and monitor an unlimited number of boards and use its True-Q lumber tracking system to make sure they get to the right destination. A True-Q on each sorter line will monitor the lumber, even recognising boards that have been cut-in-two. To comprehend the significance of this, consider that half of a cut-in-two board may get

22 International Forest Industries | AUGUST/SEPTEMBER 2013

sent to the tray sorter and the other half to the bin sorter – TrueQ must recognise both sections using only the surface image of the lumber (no ink or paint marks). “This is truly a first in our industry and is one way to take advantage of the many possible combinations of lengths and grades available from automated grading – instead of being constrained by limited sorting capacity,” Lucidyne said. IFG has a second GradeScan scheduled for installation later this Fall for its Laclede, Idaho, facility. Collum’s Lumber Products in Allendale, South Carolina, is in the fine-tuning phase of its first month of production with its new GradeScan system. The mill’s move to a Lucidyne scanner was made after thorough testing of both lineal and transverse techniques and determining that the product requirements could only be met with Lucidyne’s highresolution lineal scanner. This mill grades 25-100 mm (1-4 in) dimension and appearance products. Among some of the GradeScan installations planned for 2014 is a system for Lampe & Malphrus Lumber Company in Smithfield,

North Carolina. This February installation will see GradeScan doing more appearance grading for high-quality Southern Yellow Pine products. From due-diligence efforts leading up to its purchase decision, the mill expects to see some great improvements in grade yield and volume as productivity becomes even more consistent. Swedish laser sensor and measuring systems specialist, LIMAB, has introduced a new board scanning systems to its range of laser inspection systems. The LIMAB BoardProfiler 3D, was launched at the Ligna 2013 wood and forestry tradeshow in Germany. The system is now already running in its first installation. The BoardProfiler 3D is a board scanning system for dimensional measurements and defects detection. LIMAB said that the product builds on the success of the earlier generation BoardProfiler that is used in more than 170 sawmills all over the world. LIMAB has used its expertise in sensors to develop a new 3D laser profile sensor that provides a “much more accurate and detailed analysis of the board than previously possible”. As an

GradeScan installed at Collum’s Lumber Products on planer outfeed

SCANNING & OPTIMISATION

example, the thickness accuracy along the board is as good as +/0.05 mm. The system processes 12.5 million measurement coordinates every second. “Defects such as holes, cracks and knots as small as 2 mm² can be detected,” the company reported. “The system measures boards with high accuracy in all production speeds up to rates of 200 boards/m and is unaffected by board movements or vibrations.” In addition, the system is Windows-based and provides the user with all the measurement data information, including complete wane data, optimisation of cutting for trimmers, reject or turning before edgers and “much more”. The BoardProfiler 3D is a complete stand-alone system to measure board profiles in transversal and lineal processes. The system incorporates LIMAB’s newly developed ProfiCura 600 sensor that measures every millimetre for the best accuracy at

A BoardProfiler installation high speeds. LIMAB’s BoardProfiler 3D sensor delivers a profile scan of the board at a measurement rate of 1,000 profiles/second. The system is ideal for high-speed scanning of boards and for

optimisation and grading applications in the harsh sawmill environment. The BoardProfiler 3D system can also be combined with PreciCura 1D sensors for a more cost effective solution than a

multipoint or camera-based system.

AUGUST/SEPTEMBER 2013 | International Forest Industries 23

SCANNING & OPTIMISATION A look at BoardProfiler 3D applications Optimisation for trimmers: calculates the optimum cutting position for each board based on customers specified rule tables. Defect detection: The system looks after thickness variations, holes, cracks and knots along the board in both transversal and lineal processes. Cutting, sorting and rejecting according to deviations in specified rule tables. Reject or turning before edgers: The BoardProfiler 3D will determine which side of the board has wane so the board can be turned before the camera. Deformation measurement: The overall shape such as flat bow, side bow and twist will be determined and classified according to specified rule tables. Thickness and width sorting: The overall dimensions of finished boards are accurately measured at multiple positions along the board length for quality assurance purposes. “The innovation results in much more accurate board measurement and a higher production yield for the sawmill [and] is easy to install and has a quick payback.”

Defects detected by the BoardProfiler

Because of wide application range and high grading capacity, the BoardMaster system from FinScan is one of the most famous board grading scanner at sawmills around the world. It can be used for green grading and edger applications at the sawmill, for grading of dry and rough boards as well as for final sorting of planed boards. “When grading in the green line, it is important to remove the defects as early as possible in the production process with an automatic quality grading system,” Finscan said. “Then the drying can be optimised and the final sorting can be run with

higher capacity.” The FinScan grading system scans individual boards from all directions for fast image processing and board quality analysis. Based on required grades, it optimises the board giving detailed instructions for trimming, cutting, ripping and sorting. The system includes all common international grading rules for a wide variety of softwood species. It has also a wide selection of application programs for different remanufacturing purposes. The latest version, BoardMasterHDL, includes lots of technical improvements, many of

When grading in the green line, it is important to remove the defects as early as possible in the production process with an automatic quality grading system – Finscan

BoardMaster system from FinScan

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SCANNING & OPTIMISATION

All parameters and grading rules are refined together with our engineering teams in order to get the most out of your production – MiCROTEC

which can be implemented as upgrade kits in older installations.

Key benefits of BoardMaster • Increases the value yield of the sawmill • Optimises the production according to raw material and customer requirements • Manages complex production requirements • Secures constant quality of board production and deliveries.

EndSpy – board end analyser With EndSpy, it is possible to analyse the distance of the annual rings. It detects also cracks,

bluestain and rot in the board end. By exact detection of heart pith position, EndSpy can be used, for example, for board turner control in the planer lines.

MoistSpy – moisture analyser MoistSpy analyses the moisture of the board from up to eight positions. It performs fast and accurate moisture profile measurement, which can be used for grading and analysing of drying errors. The FinScan board grading system is being used for strength grading of structural timber. It gives comprehensive information on lumber defects and expected strength value. The system is equally well suited for large and small sawmills. FinScan has delivered over 300 board grading systems to sawmills in Europe, Russia, North-America and Asia. At Ligna this year, Microtec introduced a completely reengineered multi-sensor scanner platform. The first to have been launched was the basic edition,

Parameters are refined with the sawmill to ensure the best result is returned from the Goldeneye-500

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SCANNING & OPTIMISATION

An installation of the Microtec Goldeneye-500 Goldeneye-300, delivering multi-sensor scanning performance for sorting and grading lines up to 100 m/minute (ft/minute). On July 1, the brand new Goldeneye-500 was officially launched with the first installation completed in Romania. The Goldeneye-500 builds on the same radical design and technological innovations as the Goldeneye-300. Microtec optimisation boosts both recovery and value in wood component manufacturing. “All parameters and grading rules are refined together with our engineering teams in order to get the most out of your production,” Microtec said. “The Goldeneye series is a comprehensive

product family delivering multi-sensor solutions in order to boost recovery, quality and value for the lumber processing industry. Whether in longitudinal or in transversal transport, for green or for dry boards or panels, to rip or chop, in low or in ultra-high capacity plants, Goldeneye multi-sensor quality scanners accurately sort and grade it all.” The Goldeneye-500 has been designed with three goals in mind: • To boost value in wood component manufacturing • To make scanning more accurate and reliable • To provide advanced yet easy to use optimization solutions.

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Designed to last Multi-sensor scanning accurately and reliably detects and recognises wood properties. This allows sawmills to streamline and optimise the production strategy. The value optimisation is based on customer-specific parameters, such as defect definitions, grading, chopping and sorting rules. Goldeneye-500 is being used for sorting and grading lines up to 300 m/minute (1,000 ft/minute). The design of the Goldeneye platform is based on a modular concept and has been unified throughout the series so customers can easily upgrade their modules. Microtec takes advantage of the next generation Crometic HD-sensors, featuring an

SCANNING & OPTIMISATION

JoeScan scanners have been in sawmilling environments since 2002 and have a solid reputation for quality products with superior customer service – JoeScan

The Microtec Goldeneye-300 was the first of the Goldeneye series unveiled at Ligna Characteristics of GOLDENEYE-500 • Next generation sensors • New x-Ray technology • 64-bit power operation system for faster image processing • All new technology with modular arrangement and durable scanning performance • Go mobile with Apps for iPhone, iPad and Adroid devices • GOLDENEYE-500 is equipped with multiple cameras per side for high speed wood component manufacturing.

even faster image acquisition and a more powerful digital image processing core. The new X-ray sources have integrated cooling systems, are extremely low in maintenance, and are designed for continuous workloads – 24 hours a day, seven days a week. For the site managers who travel a lot, Microtec has developed an additional application to access the Goldeneye system with a smart device, phone or tablet. Android and iOS are both fully supported and can access all production data. “The Goldeneye-500 is a technological jewel – the best we have ever made,” Federico Giudiceandrea, CEO of Microtec, said. “We have designed the Goldeneye from ground up in order to deliver the best scanning experience for our customers: we have designed new sensors, new X-ray sources, re-engineered the internals, implemented 64 bit performance everywhere and given the scanner a brand new

housing to solve some of the tricky issues of cleaning, maintenance and upgrade requirements.”

Three models to choose from Microtec offers three models of the Goldeneye-500 (501, 502 and 506). All models have the same visual scanning options (3D scanning, colour scanning, and scatter scanning). The models 502 and 506 feature the new X-ray scanner. The 506 includes Viscan, a stress grading scanner certified by ALSC in transversal transport. The upper limit of cross-cuts is 100 mm x 225 mm (4 in x 9 in).

lamellas will be processed every year. Schweighofer management expects a significant boost in added-value with help of the multisensor scanner Goldeneye-500. The JS-20 MX is JoeScan’s medium-range scanner, ideally suited for a broad range of applications. This single-laser scanner can deliver fast and accurate measurements at an operating distance up to 2.1 m (7 ft), with a field of view up to 1,025 mm (41 in) wide. The MX is based on JoeScan’s proven and reliable JS-20 scanner

First installation in Romania Leading European woodworking company, Schweighofer, is based in Austria but has various branches across Europe, including Romania. Schweighofer’s solidwood panel manufacturing plant in Siret, Romania, was the first to have the Goldeneye-500 installed. Installation was completed in May while start-up was carried out across mid-June. The multi-sensor scanner is integrated into the lamella sorting line of system. “The scanner is a significant relief,” Schweighofer CEO Gerald Schweighofer said. “Before we had to manually sort the lamella. “After serious market research and based on the outstanding cost benefit, we chose, again, our long-term partner Microtec.” The plant managers and operators have been trained at the headquarters in Bressanone, Italy. “Plus, the start-up and the overall project management have been implemented in a serious and professional manner. We are very happy with the performance,” Schweighofer said. The grading results of each board are sent directly to the chop saw of the system, in order to control the value optimised chopping. Some 1 million m3 of

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camera images, and to configure and calibrate the scanner using a simple Web browser on their PC. The MX is fully compatible with all scanners in the JS-20 family. All scanners use JoeScan’s reliable QuickPulse laser technology, which keeps all scan heads synchronised and helps maximise the laser life. “Like all JoeScan products, this model is backed by a five-year manufacturer defect warranty and 10-year support life guarantee,” the supplier said. “JoeScan scanners have been in sawmilling environments since 2002 and

The JS-20 MX is JoeScan’s most versatile, medium range scanner. It is ideally suited for a broad range of applications that require accurate profile measurements

platform, developed to make scanning systems easier to install and maintain. It requires only 24 VDC and an Ethernet connection for operation, and it can be installed in any orientation in minutes using the optional Mount Kit. Because the scanner uses an Ethernet interface, it is easy to communicate with the scanner without special hardware or proprietary software. This interface also allows users to view real-time profile data and

Depth of View 20” to 84”

Field of View 10” @ 20” standoff 41” @ 84” standoff

JS-20 MX features • Single laser with field of view up to 1,025 mm • Scan rate up to 275 profiles/s • Scan resolution up to +/- 0.025 in • Easy-to-use Ethernet interface • One-click, automatic calibration • Encoder-synchronised scanning • Rugged, fully sealed aluminium housing • Image View feature for easy troubleshooting • Five-year defect warranty & 10-year support life guarantee. have a solid reputation for quality products with superior customer service.” Key Features • Single laser with field of view up to 41” • Scan rate up to 275 profiles per second • Scan resolution up to +/- 0.025” • Easy-to-use Ethernet interface • One-click, automatic calibration • Encoder-synchronized scanning • Rugged, fully sealed aluminum housing • Image View feature for easy troubleshooting • 5-year defect warranty & 10-year support life guarantee It has been almost 20 years since Comact first started to work on visual images in order to grade lumber. The first prototype was installed in Northern Quebec and was based around the trimmer-optimiser platform, which used only geometrical sensors back then. Later on, laser profiles coupled with colour cameras were installed on an inclined transverse transfer and the GradExpert was born. “The goal was to get into the dry end lumber market, but no one expected it to be so successful,” Comact recalled. “At the time, no one could imagine Comact having as many automatic graders in operation as it has today.” Comact uses different types of colour cameras to detect visual defects on any type of wood. Moreover, these cameras are speciallydesigned for logs, cants, flitches (sideboards), rough boards, and dressed lumber. ‘Area cameras’ (which, as you’d expect, scan areas) are used for scanning large sections of wood like log ends and mainly measure in a lineal way. ‘Linescan cameras’ (for lines) are used for scanning boards in a transverse way. Cameras are combined with lighting systems to get better image contrast of darker coloured sections such as splits, rot, and knots. LED AUGUST/SEPTEMBER 2013 | International Forest Industries 29

SCANNING & OPTIMISATION

The Comact GradExpert A close-up view of the Comact EdgeExpert

panels and/or fluorescent lamps are used for this purpose. “The main goal here is to measure geometrical and visual defects in order to get a complete grading solution, which cannot be achieved by a geometrical system alone for most of today’s demanding applications,” Comact said. The main strength of all Comact grading systems is that they are backed by the high level of

expertise of its seasoned team. The technology is there to get very accurate images of wood, but then this massive amount of data has to be processed in order to grade the wood properly. From the development of electronic design to grading optimisation algorithms, each mill process and client need is carefully assessed, programmed, and customised by senior programmers and certified

graders. This is mainly why today Comact has over 100 vision systems in operation, including 72 GradExperts running up to 250 boards/minute. Comact’s clients are located mainly in North America and use various vision applications for sorting, edging, trimming, and grading. Comact has systems, which perform in a wide range of species, namely, SPF (spruce-pinefir), jack pine, balsam fir, douglas fir, hemlock, SYP (southern yellow pine), many types of hardwood (maple, wild cherry, beech, ash, oak, aspen, etc.), white pine, red pine, cedar, red cedar, green wood, dry wood, and even radiata pine from New Zealand. With bench test capacity to run wood at its own shop in Boisbriand, QC, clients bring their own manually graded lumber to compare performances with the Comact GradExpert. Comact is especially proud of having many clients who own more than one system, among others, Canfor, with its 21 systems, is worth mentioning. This goes to say that our vision systems perform

The Comact TrimExpert

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outstandingly and that our team of experts stands behind them while leading the industry. Traditionally, MPM has supplied the wood industry with its log scanning, optimisation, and control systems. A decade ago, customer demand for lumber scanning and optimisation forced the expansion of its product line to include edgers and trimmers and, at the same time, introduced the development team to size inspection data that could be used to make inferences on upstream process issues. “A few years ago, in the depths of the downturn (and prompted by a progressive Scandinavian associate), it seemed like a good time to focus efforts on creating a stand-alone size inspection product, drawing from prior experiences with scanning technologies,” the company said. The result of these efforts was MillEye. MillEye is MPM’s current wood inspection system. This full product contains options that allow the system to either be

SCANNING & OPTIMISATION

married to an MPM centralised management system or stand alone amongst non-MPM systems. Following MPM’s philosophy of staying independent from scanner supply companies, the MillEye system interfaces to a variety of scanners, including SICK, Hermary, JoeScan, and LMI. Each scanner manufacturer has its strengths, and MPM feels that recommending the right scanner manufacturer and model for the job is one of its responsibilities. Scanning types include both single point and sheet of light, depending on the application. In some cases, higher vision components (e.g. colour, scatter) can be used to not only provide size measurement but also grade inspection and comparison against upstream grade prediction. In terms of the type of object being measured and verified, MillEye can inspect opening faces, sawn sideboards, slabs, gang-

MPM’s MillEye software provides real-time measurement feedback to operators and QC personnel MPM’s MillEye monitoring gang boards for sawing deviation and wedging sawn cants, and trimmer boards. Real-time graphs and statistics are displayed, with critical measurement limits warning the operator both visually and through other optional electronic methods (e.g. text messaging, email, reader board). “For example, saw change scheduling can be more precise as well as more reactive to circumstances that can quickly change during a shift,” MPM said.

“The amount of lost production saved through preventative maintenance actions based on accurate, real-time information rapidly covers the cost of the system. “In addition, the safety aspect of having sensors caliper all boards rather than your QC personnel entering potentially dangerous working conditions and measuring a few boards places less risk on the factory and its workers.” IFI

The amount of lost production saved through preventative maintenance actions based on accurate, real-time information rapidly covers the cost of the system – MPM Engineering

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SCANNING & OPTIMISATION – OPERATION FOCUS The True-Read grade mark reader reads any marks the check grader makes on the boards and relays them back to the optimization computer. The system then directs the PLC to adjust the Multi-Track Fence paddle positions and the trimmer's saws accordingly

USNR grading system beats expectations S

USNR's Transverse High Grader (THG) made its debut recently grading the very challenging green douglas fir at a dimension lumber mill in Oregon. Early indications are that this new grading line is meeting or exceeding the mill's targets for achieving consistent grade out, as well as improving throughput and the mill's fortunes

capital investments. He explained the reasoning trong lumber markets, an obsolete grader behind the investment in the THG line. “We had assist scanner, and the need for fencing an outdated geometric grader-assist system and accuracy created the perfect storm for were still operating with four graders,” he said. Swanson Group to invest in a fully automated “We were targeting getting the grade out grading line at its Glendale, Oregon dimension consistently day-in and day-out, as well we mill. The company chose USNR’s THG system, wanted to speed up the system and increase along with key ancillary equipment that together production.” are improving the production and grade out for Knous said they reviewed all of the major the operation. automated grading systems on the market and Swanson Group is a privately held forest quickly narrowed it down products company that to two competing has been owned and transverse systems. “We operated by the Swanson This system started up on time, sent packs of lumber to family since 1951. The be tested by both company operates four we started seeing the grade out Oregon wood processing numbers consistently filter into the systems. In the end we chose the THG based on plants: a stud mill at percentages that we wanted, and the software, the Roseburg; the dimension also started to see our production hardware and how well lumber mill at Glendale; the system functioned.” and two plywood and numbers increase within a short He went on to say that veneer plants at Glendale time of start-up – we were pretty they had also considered and Springfield. impressed with that – Doug Knous, USNR’s Lineal High The Glendale dimension Corporate Project Manager for the Grader (LHG) system, but mill processes green the transverse THG was a douglas fir in 50-100 mm Swanson operations better fit for the mill (2 in x 4 in) through 50layout. 250 mm (2 in x10 in), and Along with the THG, the Glendale mill updated 2-6 m (6-20 ft) lengths that are marketed its trimmer in-feed area with a USNR Revolver domestically. The recent major recession forced Lug Loader, MillTrak lumber flow management the company to look to new products and global system, Grade Projector, True-Read grade mark markets to ensure its continued success. In reader, Multi-Track Fence, and WinTally sorter addition to standard dimension products, the mill management system. The PLC system for the line also now produces rail ties and small timbers. was updated from PLC5 to ControlLogix. The Glendale mill is in the midst of installing dry kilns and boilers to allow it to add dry hem fir to its product mix. Window of opportunity Knous explained that the major hurdle the mill Selecting a system faced with the project was a hot market, making Doug Knous, Corporate Project Manager for the the window of opportunity very short to shut Swanson operations, manages all of the major down the line for the installation. “We had 11

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OPERATION FOCUS – SCANNING & OPTIMISATION days to rip the equipment out from landing table through the trimsaws and install new hardware, transfers, THG system, Revolver Lug Loader, new landing table, etc,” he said. “We worked 24 hours a day mechanically and 12 hours a day on the electrical side to get everything wired up. After install, we still had the task of starting up the control and optimisation systems and getting them tuned in.” Knous said the timing was an “absolute” challenge but the mill started producing on the scheduled production date. He said it was a “very good” start-up.

Speaking from experience Today, the Glendale operation has reduced its grading contingent from four manual graders down to one check grader. Knous speaks from experience when he says he is pleased and impressed with the performance of the THG. “I’ve dealt with some other automated grading systems and they have taken quite some time to get things tuned in to a comfortable level,” he said. “Above and below grade are very important to us and those tend to be finicky and take some time to get tuned in, especially with the product mix in dimension mills. “This system started up on time, and we started seeing the grade out numbers consistently filter into the percentages that we wanted. We also started to see our production numbers increase within a short time of start-up. We were pretty impressed with that.”

The bottom row of sensors is visible at the THG outfeed Knous continued to explain that the grade out is equally “as good or better” than it was with the manual system, but more consistent and with increased production. Though the performance tests haven’t yet been done, he is confident the THG is ready. “We’ve passed three inspections by the grading bureau (Western Wood Processors Association) and we’re seeing all of our grade out percentages tracking nicely to our projected targets.” Knous is convinced that as the software continues to progress and the mill gets better at tuning for its products, the system will continue to improve the mill’s fortunes.

How the system works The new USNR equipment supply begins with the MillTrak camera

We were targeting getting the grade out consistently day-in and day-out, as well we wanted to speed up the system and increase production – Knous

controlling the backlog to the Revolver Lug Loader. Once in lugs, the boards are transported on a narrow, flat transfer through the THG scan frame where they are scanned for the mill’s specified defects. The THG’s belted scanner transfer is a key advantage over competitive transverse systems that require elevation changes and tend to obscure the boards during scanning. The THG scanner transfer is a simple, flat transport system that completely stabilises the boards on thin belts that carry the boards through the scan zone.

These thin belts ensure the BioLuma 2900LVG+ sensors see as much of the four surfaces of the board as possible. The THG scanner is fitted with two rows of sensors positioned off-axis both above and below the transfer – in this way all four surfaces of the board can be scanned using only two rows of sensors. As well, the THG uses an end grain scanner positioned at lumber line that scans the end of each board, and provides the THG’s GrainMap technology with measurement data to identify the

The grade and cut/trim solutions (see boxes) are projected onto the surface of the board AUGUST/SEPTEMBER 2013 | International Forest Industries 33

SCANNING & OPTIMISATION – OPERATION FOCUS

Knowing the part of the log the board came from is critical to accurately determining how the surface knots are connected within the material – Harry Ogloff, USNR

The check grader can either agree with or change the THG's solution by making a mark on the board pith location relative to the board for highly accurate knot sizing capability. The THG software classifies the defects on each board and assigns it a grade based on the size and location of the defects together with the mill’s grade definition inputs. The check grader and Grade Projector are located immediately downstream from the THG scan frame. As the boards exit the scanner, the grade and

trim solutions are projected onto the surface of the board for the check grader to view – they can either agree with the THG’s solution by letting the board pass or override it by making a mark on the board. The True-Read grade mark reader reads any marks the check grader has made and feeds them back to the THG optimiser. The system transmits the final solution to the PLC to direct the Multi-Track Fence to adjust the

paddles to position the board, and to direct the trimmer to lower the appropriate trimsaws for the cut. One hurdle that the USNR engineering teams faced with the Glendale THG unit was grading for green doug fir. This is a very challenging species for scanning. The knots tend to be similar in colour to the rest of the wood, making them difficult to detect through visual means. ‘Wet’ wood is also challenging as the moisture

The Grade Projector is located immediately downstream from the THG with projectors mounted above the flow

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content in the wood can deflect the laser and vision scans to a degree, distorting the data. That being said, the Glendale unit has overcome these challenges based on the excellent results the mill is achieving.

The importance of pith Harry Ogloff, USNR Product Manager for automated planer grading systems, explained the importance of the THG’s proprietary end grain scanner in determining accurate knot sizing. “The purpose of the end grain scanner is to measure the grain at the end of the board to determine which part of the log the board originated from,” he said. “Knowing the part of the log the board came from is critical to accurately determining how the surface knots are connected within the material. “The end grain scanner along with other attributes of the material allows the THG to not only view the knots from the material surfaces, but also know how these knots are interconnected inside the material.” Ogloff went on to say that one key attribute for structural grading

OPERATION FOCUS – SCANNING & OPTIMISATION was the amount of knotty material that existed in a given cross section of the board. In a log, the knots typically converge toward the pith (centre of the log). To determine the volume of knotty material in a board and assess its structural properties, it is essential to know how the surface knots connect inside the board. The end grain scanner provides important data to assist the optimiser in that determination.

Strengths of this line Knous was complimentary about the ancillary equipment that was installed with the project. “The Grade Projector is a pretty valuable piece of the check grading system. The graders can see the projected grade, agree or disagree with it and make changes if they so desire.” He was particularly impressed with the Multi-Track Fence: “The fence is an outstanding system. It’s very smooth and precise and its operation has been flawless.” Knous went on to explain that paddle fences typically pose problems such as an abundance of moving parts that require fussy timing and maintenance. “With this fence we put it in, set it up and it has been smooth and problem free from start-up.” He said his experience with the Revolver Lug Loader was similar –

it went in easily and is running far better than others the mill has previously used. Knous mentioned that the MillTrak camera was working to minimise crooked boards being fed to the lug loader. “The front end of the line is running very well and that is a big piece of the production increase we’re seeing,” he said. The mill also installed USNR’s WinTally sorter management solution. One of the key strengths afforded this line is the information feedback loop capability when combining the THG automated grading system controlling the trimming process, with the WinTally system managing the sorting process. This combination offers a very powerful tool for managing product processing and package makeup. “We do some unique things with our lumber packs, and we also produce some premium grade, no-wane product,” Knous said. “The system allows us to select how we want to pull that specialty grade from our products and package it. We are utilising that capability today on a couple of items and we have plans to take that a bit further down the road. We have a lot of future potential things that we want to implement, we are just not at that stage of the project yet.”

We are pretty excited that not only are we close to meeting our targets but we will be able to surpass them going forward – Knous

Training Training is an essential element of any new process. It ensures the mill receives the best possible return on its capital investment. Training for Glendale personnel was implemented through a variety of means. The mill sent packs of lumber to USNR’s Eugene, Oregon, facility for testing on the THG during the evaluation phase of the decision making process. Glendale personnel were on hand once the purchase decision had been made, and received both theoretical (classroom) training as well as hands-on training on the Glendale unit while it was at the Eugene facility. Once installed at the mill, Glendale personnel were intimately involved in the THG start-up phase and tuning process.

Looking ahead

lumber drying capability. “Right now with the dry kilns coming on and the THG line in place, it will allow some more products as far as species go as well as dry versus green products,” he said. “With the THG, early indications are that consistency is better and we are very close to meeting or exceeding our grade out goals. We are pretty excited that not only are we close to meeting our targets but we will be able to surpass them going forward. We are consistently running more production through the system. We’ve increased speed about 10% and that is now limited by other equipment.” Knous also said the Glendale operation would have its dry kilns running by the end of 2013, and by 2014 the company expected to be producing some different products for the marketplace to allow it to be more versatile with its product mix. IFI

Knous is optimistic about the future direction of the Glendale mill with the new THG line, and with the added implementation of

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SCANNING & OPTIMISATION – OPERATION FOCUS: AUTOLOG The newly installed Autolog ProGrader linear planer optimiser at East Alabama Lumber features appearance grading in decking material

Risk, trust, success The East Alabama Lumber company and industry partner Autolog early this year challenged themselves with a seamless installation and commissioning of a state-of-the-art optimisation system

he East Alabama Lumber Company from Lafayette, Alabama, USA made the decision in early January of this year to team-up with Autolog, a leader in optimisation and controls from eastern Canada, to upgrade its planer operation with new controls and a fully optimised linear ProGrader system. The mill produces 65 mbfm/y on a single shift in southern yellow pine with products ranging from 2-5 m in length, thickness from 50-100 mm and width from 100-300 mm. Some 45% of its total production consists of decking (5/4 X 6 in) with appearance grades. Before the upgrade, grading decisions were performed by four to five graders working on a flat chain prior to the lug loader. Main equipment included a Newman 990 planer with hydraulic feed, nine saw trimmers, smart gates with cut-intwo, and a 40 bins sorter. This project faced many challenges and to be successful both East Alabama Lumber and Autolog made the commitment to team-up and work closely together. Many meetings were scheduled to plan all details and overcome any unforeseen events that would extend the duration of the project. The main objectives were to perform the install and start-up of

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all the equipment and to implement new optimisation software with appearance grading with zero downtime. Part of the project also included new A-B ControlLogic PLC and Autolog Sorter system to control the line from the planer down to the MIC (Morris) sorter; in fact,

We provide a second-tonone knowledge transfer on the many diagnostic tools, simulation software, its user-friendly interface and extensive reporting system – Autolog

the control replacement was the first phase of the project. The new PLC cabinet was installed and wired up during the week by the East Alabama Lumber electrical people and the Autolog team got on site on a Thursday afternoon to verify all connections, I/Os and train customer on the new ProSorter system. Transfer from the old PLC to the new one was performed in a total of four days. The new system was fully

operational on the Monday morning. Part two of the project was to install the ProGrader system without interfering with the production. All heavy equipment was installed on a week-end (optimiser, bridge conveyor, computer cabinet, etc) so the mill could run on the Monday with everything in place but still having the graders make decisions. With this set-up, the ProGrader was grading the boards off-line and the Autolog forest engineers were free to fine-tune the parameters and make changes to the system without any impact on the production. After a week, the system was turned on-line and the automatic grading process started. Among the challenges in this project was the ability for the ProGrader to optimise for decking material. The 5/4 radius edge decking (RED) at East Alabama Lumber was a new item for the ProGrader. It is graded with a combination of ‘best face-worst face’ rules and 50 mm (2 in) dimension rules. The ProGrader increased the amount of premium RED produced by the mill. The ProGrader was able to increase the amount of premium in some cases by cutting pieces in two and creating a premium face on each end of the cut-in-two that would

OPERATION FOCUS: AUTOLOG

The Autolog ProGrader generates a very strong uplift in all products but greatest was with 5/4 – payback will be less than a year – Joey Massingill, EAL

normally be graded a full-length standard. An increase in the amount of ‘No. 1’ produced in 50 mm x 100 mm (2 in x4 in) and 50 mm x 150 mm (2 in x 6 in) by the mill was also noted. Even if the addition of the appearance grade in 5/4 decking was challenging, the Autolog vision and optimisation group knew the end result would be highly satisfactory mostly based on the quality of the sensors, the computer power available and the way the software is designed. Instead of using self-learning and matching software, the Autolog way is to provide algorithms and parameters for each defect. The methodology allows identifying defects easily within defects. Also by doing so, the change to a particular defect does not alter other defects. For the East Alabama Lumber project, the customer sent decking material to Autolog to be tested long before the delivery date. A group of people from the client, including its local TPI representative, came over and approved its own system in the Autolog test lab before shipping. This procedure is standard at Autolog and facilitates a quick and

successful start-up. “Automatic grading is complex and can be scary for a mill without in-house technical people that may not be familiar with a graderless system,” Autolog said. “We provide a second-to-none knowledge transfer on the many diagnostic tools, simulation software, its user-friendly interface and extensive reporting system. The inherent quality of the solution comes from it sensors and their life expectancy and the redundancy built within their computer architecture.” The Autolog ProGrader features a unique QC and troubleshooting tool consisting in a board tracking system. All the data pertaining to each board is stored in a SQL database and is available on request. Up to 150,000 boards can be stored with their complete optimised solution. The frame of the machine and mechanical components are overdesigned to maintain uptime to a maximum. Multi UV ID codes ensure code readability at 100% thus eliminating board rejects. A Dynamic Grading Zone with moving colour LED displays an optimised solution for each board to help the check grader make

The Autolog ProGrader features a unique QC and troubleshooting tool consisting in a board tracking system. All the data pertaining to each board is stored in a SQL database and is available on request by keying in their ID number printed on each board. Up to 150,000 boards can be stored with their complete optimised solution better decisions. A digital production display shows production information, reasons for stoppage and system interlocks for minimal downtime. Autolog aims to provide only “top-of-the-line” products and says everything it does is backed with more than 25 years of experience. “In this industry, some companies are suppliers while others are partners – Autolog is your partner,” Autolog said. That sentiment was backed up

by Joey Massingill, Dry End Manager for East Alabama Lumber: “The Autolog ProGrader generates a very strong uplift in all products but greatest was with 5/4,” he said. “Payback will be less than a year.” “Their install team did a bangon job on a flawless execution and education. The ProGrader will grade lumber accurately and consistently at full speed.” IFI

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OPERATION FOCUS – SAW TECHNOLOGY

Vollmer part of Ernest Bennett family Celebrating its 50th year of business next year, one of the founding partners and company chairman at Ernest Bennett (Darlington) puts the company’s success down to the hard work and support of his family, long serving staff and a strategy of heavy re-investment in technology

he company was formed by my uncle Ernest Bennett and I with nothing more than a grinder and a file in my hand,” Ernest Bennett Chairman Rob Maxey recalled. “Now, we have over £3 million ($4.7 million) of machine tools, a high percentage of it being from Vollmer, some that are robotically loaded to run unmanned overnight. Times have certainly changed since 1964.” Since its inception, the County Durhambased company has evolved to be the leading manufacturer and supplier to the UK and Republic of Ireland and exporter to many countries. Ernest Bennett mainly deals in bandsaw blades, TCT & HSS circular saw blades, wood cutter blocks for profiling and profile knives, and more recently solid carbide spirals and routers for the wood and metal cutting sectors. As one of the region’s leading manufacturers and service centres, Ernest Bennett has continually expanded to fill its current 2.6 ha site – a facility of over 16 km2 (40,000 ft2) with 54 staff. The company has notched up a number of achievements through its 50-year history that have guaranteed its success. “We are proud of our zero redundancies, a significant number of our staff with over 25 years company service, and a continuous rigorous apprenticeship scheme that has been on-going since the company’s inception,” Maxey said. “The [apprenticeship program] has always taken account of any losses of

“

personnel, with apprentices quickly transferred through full one-to-one training by skilled personnel.” With company Chairman and his wife, Iris Maxey, taking a back seat, the next generation of the Maxey family has taken the reins through sons David and Simon, the Managing Director

Like any business that has a relentless commitment to supplying its client base with such frequency, we are heavily reliant on the up-time of our machine tools and the quality they produce – the Vollmer service and support team give us unparalleled confidence levels in their ability to minimise any downtime and issues that may arise with our machines – David Maxey,

the early 1960s – a wide bandsaw tensioning machine,” David Maxey said. “This was followed by a sharpening machine; a circular plate saw machine and then a TCT sharpening machine. A major turning point for us was the move from swaged bandsaws to stellite-tipped bandsaws. “We were the first and UK’s frontrunner using automated technology for the manufacture of stellite-tipped wide bandsaws. This was only achieved with the first Vollmer machines and support from the supplier.” Over the years, the company has purchased and tirelessly used Vollmer technology in its manufacturing processes, making upgrades as the technology has evolved. At this point, the business buys the next level of technology to improve its quality and product portfolio – always staying ahead of the competition. With 60% of Ernest Bennett’s turnover arriving from the production of 60-300 mm wide bandsaw blades, the company was the first in the UK to invest in Vollmer’s automatic RC100 bandsaw tensioning and levelling machine in

Ernest Bennett

and Financial Director respectively. And the company retains its longstanding relationship with Vollmer machine tools. “The first Vollmer machine acquired was in

38 International Forest Industries | AUGUST/SEPTEMBER 2013

The Ernest Bennett office in front of the factory

OPERATION FOCUS – VOLLMER

A major turning point for us was the move from swaged bandsaws to stellite-tipped bandsaws – Maxey

1998. Now running a number of RC100 machines and looking at the next generation model, Ernest Bennett has 40 machines for processing bandsaw blades – mainly Vollmer units. “As a manufacturer and service centre we have a fleet of delivery vehicles, including 7.5 t lorries, delivering to our customer base on a daily or weekly schedule,” David Maxey said. “To accommodate such punishing delivery schedules, we have invested heavily in dedicated computerised scheduling software and a purpose-built loading bay. Our investment in logistics underlines our commitment to servicing the customer base. “However, like any business that has a relentless commitment to supplying its client base with such frequency, we are heavily reliant on the up-time of our machine tools and the quality they produce. To this end, the Vollmer service and support team give us unparalleled confidence levels in their ability to minimise any downtime and issues that may arise with our machines.” With the growth of the company’s circular sawblade business, Ernest Bennett has in recent years moved from Vollmer’s manually loaded TCT sharpening machines to robot loaded cells that feed the grinding centres. The first robot loaded equipment was installed with a CHD250 grinding machine in 2005. The additional capacity and labour saving was exceptional. As Bennett's run one shift/day, the installation enabled the company to manufacture TCT blades unmanned for 14-15 hours a day as well as the eight hour manned shift. This increased capacity, profitability, reduced labour costs and enabled the company to 'future proof' its

pricing policy. The success of this equipment made such an impact that the innovative business installed a more sophisticated cell in November 2012. The new cell consists of a Vollmer ND250 loading station that has five loading stacks to feed a Vollmer CHF270 side grinding machine and a Vollmer CHD270 top and face

The CHD270 forms part of the twomachine cell at Ernest Bennett

The first robot-loaded cell acquired by Ernest Bennett in 2005

grinding machine. The new cell is recognised as a UK first with the set-up being able to fully machine new and service blades automatically. “This cell was a significant investment for us and again marks a UK first in the acquisition of Vollmer technology,” Maxey continued. “The new cell automatically checks all tooth angles and geometries and grinds our new blades as well as blades that are returned for servicing and re-grind operations. “The ability of the new Vollmer cell to automatically check, grind and polish all top side and face

angles has further improved our process capability and product quality beyond that of our competitors. Astonishingly, we can completely mix the stacks with new and re-grind blades and just turn the lights out. The following morning the stacking system will be filled with all the new and reground TCT blades ready for delivery to the customer.” As the CHD and CHF machines automatically measure the teeth and geometry on each blade prior to processing and also re-sharpen and re-calibrate the grinding wheels, the precision and quality of each and every blade is beyond

customer expectations. By measuring the blade size and geometries, the grinding centres automatically allocate the correct program for each blade to ensure re-ground blades match the quality of new blades. To identify the blades during the grinding process, Bennett's has invested in a laser etching machine to individually identify all the blades the company manufacture. “The latest Vollmer cell has taken our business to a new level with regard to TCT saw blades,” Maxey concluded. “The quality, precision and consistency of our TCT blades are second to none and this improves performance for the end user. Furthermore, the Vollmer cell has improved our efficiency, delivery lead-times, process capability and reliability whilst reducing our labour and production costs. Working with Vollmer for almost half a century has paid dividends for Ernest Bennett's and we are sure Vollmer will be part of our success going forward.” IFI

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SCANNING & OPTIMISATION – ON THE JOB

Söderhamn Eriksson technology proves global applications A string of global orders for Söderhamn Eriksson’s scanning and optimisation systems has proven its relevance to multiple markets

ince the mid-90s, Söderhamn Eriksson and leading suppliers of measuring and optimising equipment have together delivered sawlines with the sawing yields previously not thought possible. Among the company’s most recent customers to upgrade its sawline with 3D log infeed alignment, is the privately owned Swedish sawmill Wallnäs. In the summer of 2012, the mill’s 20year-old bandsaw line received a new log measuring conveyor, rotor log turner and log positioning equipment. At the same time, the old sawmill control system was replaced by Swedish system integrator Milltech. Milltech has been enjoying a long and fruitful cooperation with Canadian MPM Engineering and, jointly with Söderhamn Eriksson, obtained a large number of successful references worldwide – from Russia in the East to Chile in the West. In the delivery to Wallnäs, control and optimising systems consisted of three main portions: advanced laser measuring heads from Sick-IVP; an optimising system from MPM Engineering; as well as a Modicon TSX control system programmed and supplied by Milltech. The systems were based on the latest technology, with Festo I/O islands distributed right on the machines. All communication was handled via Ethernet. The operator supervising production both in the sawline

and edging line is assisted by two 575 mm (23 in) touch screens for process control as well as two 1,150 mm (46 in) monitors presenting optimising suggestions and not least measurement verifications of the finished centre goods leaving the last bandsaw group. New mechanics and electronics meant Wallnäs has increased its sawing yield and the mill’s total production capacity. During 2012, Söderhamn Eriksson delivered a sawline to Mauricio Muñoz in Constitucion, Chile. This SuperSaver line, Söderhamn Eriksson’s merry-goround system including one bandsaw group and a conveyor circuit, is a compact solution for high flexibility and sawing yield. Söderhamn Eriksson’s delivery of 3D log infeed alignment includes an MPM optimising system and Milltech mill control equipment. Milltech also designed and supplied all high-voltage equipment. Distributed I/O islands right on the machines and Ethernet communication everywhere are additional Milltech features. Söderhamn Eriksson’s automatic speed control system optimises the saw line’s feed speed: data are obtained from log scanning followed by crosssectional calculations based on log diameters and saw patterns, and the results of these calculations define the saw cuts for each log and the highest possible feed speed. By spring of 2012, Söderhamn Eriksson signed a contract for a

40 International Forest Industries | AUGUST/SEPTEMBER 2013

Söderhamn Eriksson will be the principal supplier of a log intake, debarking plant, sawline, edging line and waste handling line

new sawline to Bergene Holm, Norway’s largest privately owned lumber producer. By spring 2013, Söderhamn Eriksson was the principal supplier of a log intake, debarking plant, sawline, edging line and waste handling line. The plant was installed in Nidarå and has a capacity of some 100,000 m3/shift a year. Bergene Holm was most interested in sawing yield when choosing technology and supplier. The processing line comprises eight AKE bandsaws, two canters, one edger optimiser and a Cambio debarker, all manufactured by Söderhamn Eriksson. The saw line’s 3D log infeed alignment

includes an MPM optimising system and Milltech line control system. This installation is fitted with a very large contactor switchgear featuring up to 100 frequency changers, all controlled via Ethernet. New for this plant is its state-ofthe-art safety system based on CAN-bus distributed safety islands communicating via ASI with the safety equipment along the roughly 200 m long plant. This gives the customer high flexibility with the highest possible safety when accessing machines. IFI

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SHREDDERS & GRINDERS

Reclaiming profits

The Bandit 3680XP is the upgraded model of the popular Beast recyclers

International Forest Industries’ reporter Paul Moore looks through some of the more durable size reduction equipment on the market that is being applied largely for the business of recycling

he world of size reduction machinery is booming. Green energy, though it has come off in recent years as the economic strain has shaken government focus on alternative fuels, is still a part of many long-term programs across North America, Europe and parts of Australasia. Chipping machines are in high demand as businesses looking to lessen their carbon footprint seek new fuels and better quality chips. Trans-Atlantic partnerships between raw material suppliers and pellet manufacturers have been formed. As other parts of the industry look to regain their feet

We have customers all around the world using Beast recyclers, and there isn’t an application where the new XP-Series won’t make a big difference in performance and production – Bandit Industries

in an uncertain economic environment, producers of good quality chips are lining their pockets. But what is often overlooked is the other part of the size reduction game – shredding and grinding for the recycling sector. Unlike almost any other industry, recycling has gained strength in the poor economic conditions as businesses examine any alternative avenues to

provide some breathing space on tight margins. That means there are more companies looking to offload wood waste and there is big money in companies that are well-equipped to turn that ‘waste’ into a saleable product. Companies best equipped to make the most of this phenomena will have access to some of the machines featured below. These products have clear priorities: higher

uptime, better product (often through improved screening) and greater energy efficiency. Recycling groups that choose their tools carefully will continue to turn old pallets and furniture into healthy profit margins. Those who don’t will struggle. When Bandit Industries unveiled the enhanced line of XP-Series handfed chippers in the early 1990s, the company attempted to completely

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SHREDDERS & GRINDERS Versatility is defined by the Model 3680 Electric. The unit can be configured specifically for shingle grinding with technology that allows a hot mix asphalt supplement to be produced in one-pass during any season at a rate of 100 tons per hour. For wood materials, a knife configuration on the cuttermill can essentially convert your Beast into a whole tree chipper for producing valuable products for energy industries.

reset the bar for “efficiency, production and longevity in the hand-fed chipper industry. Now, Bandit’s line of Beast recyclers will carry the XP badge to reflect over 35 specific enhancements and add-ons in eight different categories, making an already world leading line of horizontal grinders even better. “Our customers are facing new challenges every day, so we are constantly working to develop and implement the changes they need to stay competitive and profitable,” Bandit Industries President Jerry Morey said. “This has been the case since the first Beast recycler in 1995, and with so many enhancements added in just the past year, we knew it was time to christen a new line of Beasts. XP stands for extra power, extra performance, extra production and extra profit, and that’s exactly what our customers can expect with the new XP-Series Beast.” Model 2680XP, 3680XP and 4680XP Beast recyclers now feature angled front in-feeds with

larger in-feed drive chains. Track Beasts feature height-adjustable pans for adjusting feed angle. A new rail system on the return side of the in-feed replaces the roller system, significantly reducing load on the tail shaft. These machines also offer a new ‘Big Mouth’ option that increases the height of the opening into the mill. An extralarge 800 mm (32 in) diameter feed wheel is optional and includes a brush deflector to better direct material into the machine. Changes continue inside the mill housing. Base door openings are now larger for easier removal of the cuttermill. Replaceable wear plates are now standard on the left side (radiator side) of the

mill base, and optional on both sides. A convenient trap door allows for cleaning in the auger area, while the auger itself is redesigned and easier to change. Several new teeth styles are available, and they are subjected to a new proprietary strengthening process delivering longer tooth life. Two-inch (50 mm) wide sizes are available for most teeth, allowing operators to run a 30-tooth setup. New teeth mounts are now compatible with knife cutterbodies, eliminating the need to change cutterbodies when switching between chipping and grinding. Freeze-hardened teeth, screens and wear items are also optional. For customers exclusively chipping with the Beast, a new chipping drum is available. For engines, adjustable pitch fans are now standard, enhancing engine cooling and fuel efficiency. Mill shafts are larger on the Model 1680XP and 2680XP to accommodate higher HP engines, which are now available for these machines. Numerous convenience options and enhancements include

redesigned fuel tanks on track machines for better steep-terrain performance, with increased fuel capacity on the Model 1680XP. Warning lights for clutch and engine operation are relocated for easier monitoring. On-board air compressors are repositioned for more convenient operation, and upgraded impact wrenches are standard. An over-band magnet is optional and recommended for both shingle and pallet grinding. These are just some of the enhancements found in the new XP-Series Beast recyclers. “We have customers all around the world using Beast recyclers, and there isn’t an application where the new XP-Series won’t make a big difference in performance and production,” Morey claimed. “Beasts will easily handle everything from waste wood to shingles and plastic, and there isn’t a better machine on the market for turning bulky chunk wood into a quality, saleable product. Whether you are grinding or chipping, the new Beast XPSeries can make a big difference in your operation.”

This adds another element of versatility to the RH1754, making it easier to move the machine around job sites and to perform tasks like windrowing material or sorting material into different piles – Rayco The Rayco 1754-240 is an economical solution for producing high quality mulch 42 International Forest Industries | AUGUST/SEPTEMBER 2013

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SHREDDERS & GRINDERS The cob within Vermeer’s HG6000TX grinder

Whether bulky branches and cuttings, rootstocks of any size, or used wood contaminated with contraries, it shreds it all down to a set particle size – Vermeer

The only thing better than a compact horizontal grinder is a compact horizontal grinder on tracks, according to machine supplier, Rayco. The company’s RH1754 horizontal grinder has become available in a selfpropelled version that rides on a heavy-duty, steel track undercarriage. “This adds another element of versatility to the RH1754, making it easier to move the machine around job sites and to perform tasks like windrowing material or sorting material into different piles,” Rayco said. The 240hp, RH1754-240 on tracks weighs just 10.2 t (20,500 lb) and is just under 2.5 m (8 ft) wide, to avoid permits when trailering. A wireless radio remote operates each track independently, to provide precise control and two speed final drives allow for creep speed or high speed travel. The RH1754 is an economical solution for producing high quality mulch from a variety of wood waste materials, pallets, wood chips, etc. “Finally, there’s a horizontal grinder on tracks within reach of the small contractor,” Rayco said. Suitable for everything from large land-clearing jobs to green-waste recycling, the Vermeer Tier 4i (Stage IIIB) HG6000 and HG6000TX horizontal grinders have a number of features that

make them ideal for a wide array of operators. Among the innovations that already make the HG6000 horizontal grinder a remarkable machine is the all-new chip drum, which allows the grinder to produce a consistent sized chip necessary for many applications, including biofuel chip production. “What we’ve found from customers is that power plants are transitioning from coal to fuel chips, this is increasing demand for chips within the biomass and biofuel markets,” Vermeer’s Ryan Marshall said. “This increase in demand led Vermeer to introduce the chip drum. It’s a more robust, fully dedicated drum with knives, so you’re not switching back and forth as you would with a fuel chip attachment.” One of the premier enhancements is the ability to modify chip size. Operators can add or remove spacers to achieve the desired chip size. The chip drum can produce chip sizes ranging from 3-38 mm (0.125-1.5 in) with 3 mm (0.125 in) increment adjustments. “From fuel chips to playground base to fuel pellets, the drum design creates a more useful, higher quality chip,” Marshall said. A major advantage of the new chipper drum is serviceability. A number of the high wear areas of the drum are protected by

Vermeer’s HG6000TX kit 44 International Forest Industries | AUGUST/SEPTEMBER 2013

hardened steel parts providing longer life. These hardened steel parts are also replaceable via threaded fasteners to reduce labour costs and minimise downtime. Helping to minimise operator cost, screws have replaced the need for Babbitt on the knives. A user can now simply adjust the knife via thread fasteners quickly and safely rather than melting Babbitt. Peterson have a complete range of rugged machines designed for high-volume producers with demanding end product specifications. They specialise in developing delivery and processing equipment that turns low-grade organic materials into high value products. We detail just three of the machines on offer. 2750C Electric Horizontal Grinder High Production Waste Wood Grinding for stationary or semistationary operations Powered by two 300 horsepower electric motors, the Peterson 2750C provides plenty of power in a compact, high production horizontal grinder. The 2750C is ideal for operations that can take advantage of stationary or semistationary operations. Electric power costs are typically much lower than diesel fuel costs, and in today’s changing economy,

electric power may just be the answer to increasing your profits. With a feed opening of 60¾ x 32 inches combined with Peterson’s high lift feed roll for an optional opening up to 44 inches high, the 2750C can readily reduce a wide range of material. The 2750C utilizes Peterson’s new generation Impact Release System that can be set in the detent mode to provide consistent product sizing or switched to the floating anvil mode for a primary reduction where accurate sizing is less critical. The floating anvil mode provides a high production primary reduction with more protection from contaminated feedstocks, and reduces energy consumption. Another major innovation is Peterson’s Impact Cushion System. Urethane cushions allow movement of the compression roll and anvil housing pivot shaft, cushioning impacts due to contaminants in the feed material. Shear pins above the cushion combined with a sensing circuit to stop the engine help protect the shaft from catastrophic damage in the event of a severe impact. The 2750C features a large grate area that enables the 2750C to produce materials to exact specifications. Our quick-change multiple grate system makes it easy to customize grate configurations to produce a wide variety of finished materials. Grates are removed through an access door on the side wall of the 2750C. 4710B Track Mounted Horizontal Grinder The 4710B is designed for highvolume producers with very demanding end-product specifications. The Peterson model 4710B Horizontal Recycler is a track mounted version of the popular model 4700B trailer

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mounted Horizontal Recycler. The recycler has 18 inches (457mm) of ground clearance making this model particularly suited for land clearing operations or other applications where mobility is desired. Track mounting also reduces material handling costs in conventional recycling yards as wel • Adaptive Control System • Peterson’s three-stage grinding process • Quick-change multiple grate system • Innovative latching Impact Release System • Impact Cushion System • Rotor options; “drum” style and “pinned” style 5710C Track Mounted Horizontal Grinder Peterson brought a tracked, 5710C horizontal grinder to Elmia Wood show. Quickly becoming one of the most popular grinders in its product line, the Peterson 5710C has the ideal combination of horsepower, machine weight, and throughput that has proven to be a winner in this size category. “The 5710C was a definite hit at the 2013 Elmia Wood show” said Michael Spreadbury, marketing manager for Peterson. “We had a large pile of stumps and other mixed biomass that the show organizers had brought for us to grind—many people would not want to run that kind of material through the

machine, but that is exactly the kind of product that people use these machines for every day. I think we really opened some eyes with how quickly the 5710C could process the stumps into biofuel. We equipped this machine with a mix of standard and knife edge bits, and the processed material coming off the end of the conveyor was clean and consistent—just what biomass fuel buyers are looking for.” Powered by the Caterpillar C27 or C32 engine, this grinder provides the highest power to weight ratio of any Peterson grinder. At approximately 86,000 pounds (39000 kg) the 5710C was designed for operations requiring high production and frequent moves between jobs. With a feed opening of 60 x 44 in. (152 x 102 cm) combined with Peterson’s high lift feed roll, the 5710C can readily reduce a wide range of material including stumps. The 5710C features a large grate area that enables the 5710C to produce materials to exact specifications. The quickchange multiple grate system makes it easy to customize grate configurations to produce a wide variety of finished materials. Grates are removed through an access door on the side wall of the 5710C. Another major innovation included on the 5710C is

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Peterson 5710C Track Mounted Horizontal Grinder

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SHREDDERS & GRINDERS

2750C Electric Horizontal Grinder

two 2.8 m counter-rotating toothed drums provide active feed as in other Crambos. “Whether bulky branches and cuttings, rootstocks of any size, or used wood contaminated with contraries, it shreds it all down to a set particle size,” Vermeer said. The degree of shredding can be adjusted flexibly, either by changing the screen basket or even more conveniently by changing the entire screen basket cartridge – the machine is then

The Crambo direct’s new mechanical drive naturally has a direct effect on the machine’s economy. “It uses up to 30% less fuel than conventional diesel-hydraulic shredders, for much lower specific operating costs and in particular a smaller environmental footprint – all arguments that speak volumes for Komptech’s rigorous implementation of Green Efficiency.”

ready for a new job. The BioBasket XL is also new. It lets operators get more fuel product out of green cuttings, while reducing their own fuel consumption in the process. The Crambo direct is powered by a Caterpillar Level IIIB or IV diesel engine with the latest exhaust scrubbing. The whole engine compartment was redesigned, and now offers even easier service and maintenance access. Special insulation reduces noise emissions.

Doppstadts range of shredders and grinders are designed using precision German engineering to produce the very best quality machinery for the waste, composting, wood processing and recycling industries. Their robust shredders and grinders include the high speed AK, the slow speed DW or combination of both, the DZ series. With this extensive choice, Doppstadt can offer the right machine for your application As one of the market leaders globally for shredding and grinding equipment, Doppstadt also produce a wide range of other equipment tailored to applications for the production of Refuse Derived Fuel (RDF), Biomass for Energy, volume reduction and recycling. Here we look at: The Doppstadt DW 3060 is a high volume slow speed shredder. Available in both wheeled and tracked version for maximum versatility, the DW 3060 is designed on the single-shaft principle. For machinery protection and quick application changes, the DW 3060 shredder is

4710B Track Mounted Horizontal Grinder Peterson’s Impact Cushion System. Urethane cushions allow movement of the compression roll/anvil housing pivot shaft, cushioning impacts due to contaminants in the feed material. Shear pins above the cushion and a sensing circuit that stop the engine help protect the shaft from catastrophic damage in the event of a severe impact. With the Crambo direct, Komptech has brought another machine from its Green Efficiency line to market. From the newly developed drive to the extra large dimensions, this represents a new generation of shredding machine. Green Efficiency stands for new technologies with substantially higher energy efficiency than the machines and systems currently considered state-of-the-art. This

new approach to efficiency is evident not just in the drive train but also in the shredding action, the user-friendliness and, naturally, the overall economy of the Crambo direct. The Crambo direct has a drive train that combines the functionality of hydraulic drive with the efficiency of mechanical drive. That means exceptional economy, while retaining all product benefits like overload protection, reversibility, adaptation to the material etc. The new operating panel uses symbols that are clearly understandable without text. The menu guidance follows a logic that is easy to understand, and the screen images all machine functions clearly. “This virtually precludes operator error,” Vermeer said. In the large shredding chamber,

The new Crambo direct has much lower fuel consumption combined with higher performance – Green Efficiency in every sense of the term 48 International Forest Industries | AUGUST/SEPTEMBER 2013

SHREDDERS & GRINDERS

The AK 430 grinder is extremely versatile and it suited to grinding a wide variety of materials including wood waste

swinging flail holders with replaceable flail tips, this high speed grinder is unrivaled. The quickly replaceable grinding system is unique and the final product can be changed in less than 15 minutes. IFI

fitted with a hydraulically controlled shredding comb. Thanks to various, quickly replaceable tools, the DW 3060 can be adjusted to the different shredding tasks. The efficient mechanic power transmission is carried out by a direct drive with planetary gear. The noise level and the fuel consumption of the electronically controlled Mercedes-Benz motor are very low. The DW 3060 can be utilised as a wood shredder or is equally at home on a wide range of materials such as C&I waste, MSW waste, general waste, pallets, rigid plastics and the shredding of green waste. • 21 roller teeth and 22 combs shred the material • The cooler is easily accessible. For self-cleaning, the large fan wheel is reversible. The slow speed keeps down the noise level. • Powerful direct drive with electric reversing function. The motor is easily accessible from 2 sides. • The roller teeth tear the material

through the hydraulically controlled shredding comb, the comb opens automatically in case of large unshreddable contaminants in order to protect the machine and to reduce the tool wear. • The comb elements are secured by wedges, easily accessible from outside and thus quickly replaceable. • Easy operation, exact adjustment and reading of the machine data ensured with a multifunction display. The machine can be moved by wheel loader. Machine operation by remote control*. • Short setup times thanks to the hydraulically foldable rear conveyor. The AK 430 grinder is extremely versatile and it suited to grinding a wide variety of materials including wood waste, processing green waste and other grinding applications. The wood grinder is capable of a high throughput rate and is fitted with a patented loadsensing material feed. Thanks to the heavy gyrating mass, the flail drum with 1000 rpm and the free-

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SHREDDERS & GRINDERS – OPERATION FOCUS

Going green The Morbark-Orange woodyard at Kappen Tree Service

Switching to environmentally friendly electric grinding, screening and colourising equipment nets huge savings. Larry Trojak, reports.

ithout a doubt, one of the biggest obstacles care, but has really established itself doing line facing business today is the instability of clearing for many of Michigan’s larger utility fuel costs. Prices, it seems, rise without companies. Debris from those projects is collected at warning then stabilise, drop, and begin their various staging sites throughout the state and then unexplained rise all over again – but from a new, brought back to a processing facility in Marlette to be higher plateau than before. processed into mulch. It is there, according to Kappen, Companies for which fuel usage is a major that the real effect of rising fuels costs was felt. component of their operating costs are being forced to “At any given time, we have about 70 trucks out on find new ways to cope with this madness or risk the road, clearing for the utilities and generating wood literally being priced out of business. Not one to be waste,” he said. “In addition, we also collect green forced into a corner of any kind, Warren Kappen, cowaste from smaller municipalities in the region and owner of have the general Kappen Tree public bringing Service, looked us clean debris. at the mulch “In the past, Each one of our machines was diesel-powered – facet of his everything the grinder alone was a 1,000 hp unit – so our operation and brought in to the fuel consumption was huge – Warren Kappen, identified Marlette site was changes he first run through Kappen Tree Service could make to a horizontal reduce fuel grinder, then consumption screened in a and the impact it had on his bottom line. He found it trommel, prior to being fed into a colourising unit. by replacing several of the diesel-powered Each one of those machines was diesel-powered – the components used to grind, screen and colour material grinder alone was a 1,000 hp unit – so our fuel to create high-quality mulch with electric-powered consumption was huge.” units. Doing so resulted in a reduction in power costs Kappen is not prone to exaggeration. In its previous for that part of the business of more than 90% – and set-up, the 1,000 hp grinder to which he refers burned an ability to finally loosen the stranglehold such costs about 136 litres/h (30 gallons/h) of diesel, while a had on his business. diesel-powered trommel and colourising machine each burned another 23 litres/h (five gallons/h). As fuel Feeling the pinch costs fluctuated, always settling higher than in the Based out of Cass City, Michigan, Kappen Tree Service past, he knew a change, both in his fuel source and in specialises in both commercial and residential tree the way he processed incoming material, was needed.

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IFI_PG50_Shredders & Grinders OP Focus_01 29/08/2013 13:12 Page 51

What not to grind One of the first things Kappen realised was that running all their debris though the grinder was definitely overkill – and a costly effort in more ways than one. “The overwhelming bulk of the material we take in is from our line crews and has already been run through one of the portable Morbark chippers they take with them to each site,” he said. “Since it is essentially already downsized, we knew that, by reconfiguring the process and screening out material that could be sent directly to the colourising unit, we could dramatically reduce the need for grinding. “In addition, grinding material that was already downsized out in the field was generating huge volumes of fines for us – material that was unnecessarily wasting both colourant and water. So it was simple: reduce the volume of fines, and we reduce that waste.” The best way they found to achieve that was by adding a dual-deck screen in advance of any grinding effort. In this way, all the ideal-sized material – such as that coming in from the line crews –could be

screened out and sent directly for colourising, while oversized material could be sent to the grinder for further downsizing. Fines could also be segregated out and set aside for subsequent use.

Diesel’s wild ride With a solid approach in mind, Kappen and his team started researching electric power as a viable alternative to diesel. That work included looking at historical prices for each fuel source, determining the costs associated with making the switch to electric, and researching manufacturers who could best meet their needs.

What we got far exceeded what even we thought we’d see in terms of savings – Kappen

“We looked at how electric power had trended over the last 20 years or so versus the same period for diesel and saw that there was a lot more stability in the electric market,” he said. “Diesel has spiked as high as

$22.70/litre ($5/gallon) in the past and even for larger companies like ours, it’s tough to adjust to that kind of fluctuation; electric just seemed the right way to go.” He adds that a longstanding relationship with Morbark, evident in the fleet of more than 75 orange machines the company currently runs, led him to begin talks with the local manufacturer about both the grinder and the shaker screen in electric configurations. From there, he moved on to looking for an electric colourising unit to compliment the operation.

Savings abound The net result of the effort was an undeniably state-ofthe-art wood waste processing facility, the centrepiece of which is the trio of electric screener, grinder and colourising unit. Fast and efficient, material is taken directly from yard piles and placed into a load hopper, which feeds the Morbark 7 X 18 dual-deck screen (the top deck is 1 in, the bottom is 5/8 in). Everything that comes off the screener as acceptable goes directly to the colouring machine, while rejects or overs are sent back to the grinder for reprocessing. The grinder itself, a Morbark

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SHREDDERS & GRINDERS – OPERATION FOCUS

The overwhelming bulk of the material we take in is from our line crews and has already been run through one of the portable Morbark chippers they take with them to each site – it is essentially already downsized – Kappen

Not only are power costs down but the quality of product is up 3800 Wood Hog, features a pair of 300 hp electric motors to run the mill and one 100 hp electric motor to power the hydraulics. “The savings are the real deal in this, and they are evident in so many areas,” Kappen said. “For one, because the grinder will only be handling the overs that come off the screener and our incoming material coming has already been chipped, the wear on the unit is only going to be a fraction of what it was in the past. “Those savings are compounded by the fact that the bulk of the work is being done by the screening unit, which can be run for a tenth of the cost of the grinder. And the whole screening/grinding/colouring operation is much quieter than anything else at the site –a far cry from what it was in the past. The icing on the cake for me is the fact that this part of the operation can now be done by just one man. The loader operator has control over the whole process – that’s a really nice benefit.” He added that the colourising unit the

so – suffice it to say, he was not disappointed. “With the full diesel setup, our monthly operating costs for that part were about $24,000,” he said. “We got our first electric bill the other day and were floored to see that it was only $1,800. Now, granted, there was a fair amount of outlay getting to this point; costs to get the electric service in place, capital costs for the equipment, and so on. But what we got far exceeded what even we thought we’d see in terms of savings. “In addition, the product quality is much better now, we’ve streamlined the whole operation, and there is the obvious reduction in diesel emissions.” Kappen said the company was really excited about further growing the mulch side of the business, adding that the demand for product is definitely there. “When you consider that companies are currently bringing in mulch from as far away as the Upper Peninsula of the state – about 250 miles (400 km) away – the changes we’ve made have put us in a great position to be more than competitive.” IFI

company eventually selected, a Sahara X3 from Colorbiotics, is equally impressive. Rated to produce coloured mulch at a rate of up to 300 yards/h, it features a sensor that shuts down the colourising effort when product has stopped flowing to it. “They really engineered this machine to eliminate waste,” Kappen said. “Colourant is expensive, anywhere from $0.80/lb to a $1/lb, and it takes about 3 lb/yard to get the colour we like, so keeping waste down is key. It is also a fast machine, capable of giving us eight loads/day – better than 1,000 yards – which will serve us well in our busy season.”

Hard numbers, easy to take Even though he was confident in the knowledge he accrued during the research phase of the switchover, Kappen was still anxious to see real comparative numbers once the electric operation had been in use for a while. Having started this past April, he was finally able to do

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November 6-8 2013

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SKIDDERS

Loggers keep eye on costs

The John Deere 848H grapple skidder

hough economic conditions are slowly beginning to improve, high fuel costs continue to affect the forestry industry worldwide. To remain competitive, loggers continue to have a need for improved productivity and uptime, as well as low operating costs for their equipment. In summary, they need a smart machine that doesn’t guzzle fuel, and skidders are no exception. John Deere has one of the industry’s widest range of skidder models with different sizes, power and options “for any logger’s needs”. “No matter which option you choose one constant stays the same – fuel efficiency,” the

manufacturer said. “With their long wheelbase and wide stance, John Deere’s stable skidders go where you want them to go. They’ll pull faster, and most importantly, won’t surprise you when you fill up the tank.” By leveraging John Deere Power Systems technologies and the PowerTech Plus engines, the group’s skidders have delivered on their customers’ demand for greater fuel efficiency. The H-Series Skidders are built to meet these productivity and operational challenges. Perhaps the biggest contribution to the H-Series’ fuel efficiency is the fieldproven 6.8L Tier III PowerTech Plus emission-certified diesel

engine. The fuel economy is reportedly second-to-none, while packing the HP needed to move the lowest cost per tonne. The H-series also features the popular AutoShift functionality that eliminates the need to shift by automatically selecting the optimum gear based on the load. This allows operators to use their right hand to run the grapple and focus on pulling the load, which effectively makes the Skidder easier to operate and increases productivity. The 748H autoreversing fan keeps the engine and fuel cooler while blowing away clogs that reduce efficiency. Its grapple has a huge 4 m2 area with a 3,250

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SKIDDERS

The new Tigercat 615C skidder has a full complement of features but with a lower initial price mm (130 in) wide opening that can deliver more wood to the landing with fewer skids. Also contributing to a skidder’s fuel efficiency is maintenance. As with all forestry equipment, skidders need proper maintenance to ensure maximum productivity. John Deere’s JDLink machine monitoring system keeps track of maintenance and monitors a machine’s health. The system, available as a website – JDLink.com – and iPhone application, allows for remote access to fleet location, fleet use and unparalleled diagnostic data. “By logging on to their accounts, customers can easily see what equipment is earning and which machines are idling while keeping preventativemaintenance tabs on each machine,” John Deere said. “The service interprets machine data from JDLink, technician inspections and fluid analysis, and advises the best methods to

proactively control machine health. By simplifying maintenance scheduling and documenting, JDLink assures that equipment is running as efficiently as possible.” The monitoring system also boosts uptime by alerting customers of potential downtime and documenting machine and operator productivity. In addition to fuel-efficient features, John Deere skidders recently gained a significant increase in performance with a new optional wheel weight package that will add 860 kg (1,900 lb) to the front of the machines. The kit is compatible with the 640H cable skidder and 648H, 748H and 848H grapple skidders. This is a simple solution that increases machine capabilities to help John Deere’s customers become more productive on the job. “Loggers will see a substantial difference in the load weight they

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are able to pull with the heavier set of wheels,” John Deere said. The weight package, made for only the front two wheels, requires the use of dual ring wheels and SWEDA axles. New wheels with a dual ring that allow the use of 35.5 tyres are also available with the optional weight package. This new wheel is available both as a factory option and field kit. Tigercat has developed a full line of skidders that lead the industry in durability, reliability productivity, fuel efficiency, operator comfort and ergonomics. All Tigercat skidders are designed and built for extreme duty conditions with strength optimised frames, robust, wellprotected cylinders and a strong centre section with large pins and tapered roller bearings. Access to daily service points is and major components is easy, with a spacious engine house and tilt cab

for access to the pumps, motors and driveline. The belly pans are generously sized. Visibility is excellent with clear sight lines to all wheels as well as through the arch to the load. The cab is large and comfortable.

Advantages of hydrostatic drive There are many advantages to Tigercat’s unique electronically controlled hydrostatic drive system including increased efficiency and performance and reduced operator fatigue. In addition, drive characteristics are identical whether in forward or reverse. Combining electronic control technology with a hydrostatic drive system has allowed the 615C skidder to operate at variable engine RPM, automatically increasing engine speed when additional HP is demanded. The result is improved fuel economy and reduced engine noise.

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SKIDDERS

With the 615C, contractors can now have all the advantages of a six-wheel drive skidder – excellent traction, high performance in steep and soft terrain and a smoother ride – in a compact package with a lower initial purchase price – Tigercat

The Tigercat 630D skidder at work in the Alberta winter

No gear shifting is required. The operator commands infinitely variable speed control from zero to maximum simply by depressing the foot pedal. The skidder operator does not have to continually shift to maintain the optimal gear for the terrain. Operator fatigue is significantly reduced. Because full torque is available

at any engine speed, breakout performance is significantly better than conventional skidders. The wheels will maintain the speed commanded by the drive pedal, regardless of the traction or pulling torque required. When maximum HP is reached, speed reduction occurs automatically. Smooth and continuous traction allows Tigercat skidders to

operate with minimal wheel spin. The result is reduced site disturbance, longer tyre life, less driveline stress and improved performance in soft or steep terrain. Because skidder travel ceases as the drive pedal is released on Tigercat skidders, the secondary braking system is almost redundant. Brake service is

seldom required because secondary braking is rarely used. The operator can maintain excellent vehicle control on slopes.

The line-up At 142 kW (190 hp), the 604C cable skidder and 610C grapple skidders share the same engine, drive system, cab and hydraulics

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SKIDDERS The 535C Caterpillar wheel skidder

Significant structural, powertrain, hydraulic and attachment changes are part of our continued commitment to delivering critical customer requirements – Caterpillar

grapple with a wide tip-to-tip opening for irregular bunches and an automatic variable pitch, reversing fan for improved fuel economy and excellent cooling performance.

Efficient High Speed (EHS)

The 527 Caterpillar track skidder systems. The machines are quick, agile and fuel efficient. The 604C is well suited to selective hardwood logging and steep terrain while the 610C is a versatile skidder well suited to a variety of clear fell, thinning applications and specialty selective felling applications. Both machines offer excellent performance in soft and steep terrain. The 620D, 630D and 635D models are all available with the largest capacity grapples and widest tip-to-tip openings in their respective size classes. The 620D is rated at 164 kW (220 hp) while the 630D and 635D have 194 kW (260 hp). The 620D and 630D are suited to the vast majority of the world’s high production skidding applications, commonly used in clear fell and plantation thinning applications, steep ground and soft soil. The six-wheel drive 635D with its long wheelbase, low-ground pressure and massive grapple is

designed for long hauls, extremely heavy loads and very soft or steep terrain. The 635D is also approved for use in demanding, high duty cycle ground scarification applications and is proving to be the ideal carrier for scarifying. The 615C is Tigercat's newest skidder, a quick, compact, sixwheel drive machine, according to the manufacturer. “Similar in capacity to the 630D, the 615C is a niche machine best suited to extremely soft or steep terrain when volumes cannot justify the massive production potential of the 635D or when tight spaces limit the ability of the 635D to operate effectively,” Tigercat stated. “With the 615C, contractors can now have all the advantages of a six-wheel drive skidder – excellent traction, high performance in steep and soft terrain and a smoother ride – in a compact package with a lower initial purchase price.” Other benefits include the high capacity, dual-cylinder Tigercat

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Equipped as standard in the 610C and 615C is Tigercat’s new EHS (efficient high speed) drive system. Similar to the standard hydrostatic drive system, EHS consists of two variable displacement motors as inputs to the Tigercat transfer case. Front and rear output shafts are connected directly to the front and rear axles. While the current electronically controlled hydrostatic drive system found in the D-series skidders performs exceptionally well, EHS is capable of providing the tractive effort of the deepest gear ratio offered in Tigercat's standard transfer case as well as the top speed of the shallowest gear ratio offered in the standard transfer case. This is accomplished with more sophisticated computer logic and the ability to take one of the drive motors offline when high tractive effort is not required. In this case, all pump flow is directed to one hydraulic motor, increasing both travel speed and motor efficiency. When operating conditions demand high tractive effort, both hydrostatic motors are working. When tractive effort requirements

are minimal – for instance, when traveling empty – all of the pump flow is directed to one motor for higher travel speeds.

Turnaround One of the most unique and innovative features of the skidders is ‘Turnaround’. The rotating seat has a two-position mechanical lock and provides full rear-facing drive capability and control of all functions. An armrest-mounted joystick controls the steering function for improved ergonomics. Drive pedals are located at both the front and rear of the cab. “With ‘Turnaround’, forward and reverse have become meaningless terminology,” Tigercat stated. “The operator has control of all machine functions in either seating position and can drive comfortably with the full speed range available either bladeforward or grapple-forward.” Combined with Tigercat's hydrostatic driveline, ‘Turnaround’ is an asset in many skidding applications where long reverses are necessary such as first thinning applications where the skidder must back down the thinning corridors as well as short haul skidding where the time and fuel required to turn the machine around has an adverse effect on productivity and increases costs. ‘Turnaround’ is also useful for picking up double bunches, loading the grapple with roadside debris and angling and placing the load optimally for the processors

SKIDDERS

at roadside as well as other decking duties. Recent upgrades to the Caterpillar C Series wheel skidders have increased performance, reliability and durability of these workhorses, the manufacturer said. “Significant structural, powertrain, hydraulic and attachment changes are part of our continued commitment to delivering critical customer requirements,” Matt McDonald, a Product Performance Engineer with Caterpillar Forest Products, said. The Cat C Series line includes the 545C with 173 kW (232 hp) gross engine power, the 535C at 163 kW (218 hp) gross, and the 525C with 146 kW (196 hp) gross engine power. The 525C is also offered with a DualHP option that provides increased power for greater productivity in first gear torque converter lock-up through fifth gear. The C Series skidders are equipped with the Cat C7 engine featuring ACERT Technology. The C7 delivers power and torque to maximise productivity and the ACERT Technology combines improvements in fuel delivery, air management and electronic control to optimise engine performance. The cooling system has a coarse fin-spacing design to keep dust out and the engine running cool. The cleanburning engine, along with proper oil sampling, allows oil change intervals to be extended up to 500 hours. The five-speed transmission matches engine power to the load size and ground conditions and electronic shift control boosts total productivity. A lock-up clutch torque converter equips the C Series skidders with all of the operating advantages of torque converter operation as

well as the speed and fuel efficiency of direct drive. The lock-up clutch allows the skidder to be operated either in converter drive for greater pull or direct drive for faster travel speeds and the most fuel efficiency. Travel speeds can be as much as 15% higher with the lock-up clutch engaged. “It’s easier on the operator and the machine is more productive. It also helps the tyres to last longer by preventing wheel spin while starting a load,” McDonald said. The variable displacement hydraulic pump draws engine power only when machine functions demand flow or pressure. This conserves engine HP and increases fuel efficiency. Recent refinements to the hydraulic system improve consistency and reduce the noise level in the cab. The wall thickness of all hydraulic tubes has been increased — double for the dozer tubes — and the flanges are more robust. The C Series wheel skidders use a weight-forward design for better balance and exceptional stability on grades, even when skidding a large load. The box section structure set the industry standard for reliable, durable main frames. The centre section is robust and durable with heavy-duty pins and structures. Upgrades to the structure include strengthening the sweep mounting and the fenders. Also, a plate added to the boom prevents damage to the grapple control hoses at the hinge between the arch and boom. Cat bunching grapples feature a strong box-section design and higher clamping forces for faster log loading and excellent hold on a load. The ‘Auto-Grab’ grapple hydraulic system monitors and adjusts tong pressure as

needed to maintain a secure grip on grapple loads without wasting power. Key structural improvements to the grapple include threaded tong pins instead of the flag style pin, thicker and larger support gussets, larger tong pin reinforcing plates and a stronger center plate to improve support for the bottom access cover. “The new threaded pin design significantly improves rigidity and keeps the pin under tension to reduce any opportunity for the nut to loosen,” McDonald explained. Caterpillar Forest Products also offers a track skidder. The Cat 527 delivers the balance and power needed for safe and productive skidding in steep or poor ground conditions. The skidder is available in a variety of track and grapple or cable configurations to suit loggers’ requirements in the AsiaPacific region, South America, Africa and the Middle East. The skidder is equipped with the 127 kW (166 hp) Cat 3304 DIT engine. Balance is achieved through optimal weight distribution and the extended track roller frame. This also reduces overall ground pressure for skidding on soft ground. The torque converter power train and three-speed transmission deliver high HP for more drawbar pull, improved skidding performance and ease of operation. Caterpillar’s elevated sprocket design provides a 711 mm (28 in) ground clearance for a smoother ride. Cat heavy-duty track components extend undercarriage life. In grapple skidder applications, the Cat swing boom increases productivity and reduces soil disturbance. The cable skidder is durable and productive with a winch capable of 31,389 kg (69,200 lb) of line pull. IFI

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IFI_PG58_59 Company Focus Bandit_HR 29/08/2013 14:11 Page 58

COMPANY FOCUS – BANDIT INDUSTRIES This forwarder is only a latest few processing TheRottne Bandit 3680XP is part of the XP-Series steps which from being shipped a customer of machines, is furnished withto more than 35 different enhancements

This year Bandit Industries celebrates 30 years of successful machine development and sales

Be brave and thrive In our modern world, the average age of a company is 15 years. This year, Bandit Industries turns 30. A company doesn’t reach this milestone by accident, or good luck, or even by having good ideas

andit was born out of a bold move and being bold is why Bandit continues to expand aggressively 30 years after the company’s origin,” the company told International Forest Industries. “Being bold is why Bandit reached far beyond the initial hand-fed chipper design that made the company famous, creating several lines of specialty wood processing equipment including large whole tree chippers, stump grinders, horizontal wood waste recyclers, forestry mowers, and yard waste processors. “Being bold is why Bandit holds patents on numerous industry-specific designs and components, developed through extensive research and customer feedback. As a result, Bandit has a product for virtually any woods-related application.” When it comes to high-production whole tree chipping, many loggers over the years have turned to Bandit’s line of whole-tree chippers because of the company’s reputation for solid production, reliability, and chip quality. The range of units has also played its part. Bandit has several disc and drum-style whole-tree chippers that cover the spectrum of applications, with the largest machines able to process a 540 mm (36 in) diameter whole tree while filling a semi-trailer in eight minutes. New technologies for Bandit whole tree chippers have given these machines a considerable advantage in biomass markets. New finger screening/breaking systems further enhance chip quality by breaking up larger material, creating a

“

58 International Forest Industries | AUGUST/SEPTEMBER 2013

highly uniform chip of exceptional quality to meet the most stringent of demands for biomass markets. Bandit’s new specialised microchip drum head for whole-tree chippers uses a specialised knife arrangement and proprietary designs to produce the highest quality quarter-inch chips available. The quality of these microchips is such that companies actively seek material specifically from Bandit machines – and the supplier says clients are willing to pay a premium to get them. Bandit pioneered self-propelled track whole-tree chippers with the world's first unit of this type back in 1990. By taking the chipper to the trees, Bandit track whole-tree chippers provide the extra mobility and productivity demanded by many logging, land clearing and biomass professionals, especially in steep or swampy terrain. Bandit continues to be a leader in this segment, providing Caterpillar track undercarriages as an option for every hand-fed and whole-tree chipper in the line-up. Bandit machines use heavy-duty welded construction with the strongest components available, all Bandit chippers and can be backed with a five-year GUTS warranty for the disc/drum, feed systems, and related equipment. Beast horizontal grinders have been one of the wood waste processing machines of choice for numerous industries since the mid-1990s. For 2013, the entire Beast line is made even better with over 35 different enhancements in eight categories. Now called the Beast XP-Series, these machines have few rivals when it comes to processing everything

BANDIT INDUSTRIES – COMPANY FOCUS The Bandit Model 2590 whole-tree chipper

Bandit was born out of a bold move and being bold is why Bandit continues to expand aggressively 30 years after the company’s origin

from brush, slash, and difficult chunk wood to create a valuable end-product. Bandit prime movers with forestry mower attachments have become extremely popular frontline site clearing machines for a variety of applications, including utility line clearing, gas and oil exploration, road construction and more. These machines are ROPS/FOPS/OPS certified and feature both stump grinder heads and rugged, Bandit-designed mower heads. High-capacity, heavy-duty hydraulic systems ensure the cutting head receives maximum power, allowing these machines to easily mow and mulch large diameter trees. Four models are available – the Model 3000, Model 3500, Model 4000 and Model 5000. Thirty years is a long time to be in business, but Bandit isn’t slowing down anytime soon. In just the last two years, the company has added 34 new dealers worldwide while nearly doubling sales volume, all at a time when many other

manufacturers are struggling. “Having rugged, dependable equipment is a big part of that,” the supplier told IFI. “Backing up

that equipment with the highest level of customer service is also a big part of that. Having devoted customers, a dedicated workforce,

a customer-focused dealer network and strong leadership is definitely part of that. “But it’s all for nothing without a bold determination to not follow the leader, but be the leader. That’s the Bandit difference.” IFI

Bandit Model 5000T with Stump Grinder attachment

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IFI_PG60-64_Company Focus Rottne_HR 29/08/2013 14:14 Page 60

COMPANY FOCUS – ROTTNE This Rottne forwarder is only a few processing steps from being shipped to a customer

Into the blue International Forest Industries took the opportunity to visit local Swedish success story, Rottne, in the lead up to Elmia to get an advance look at the new technology that would be on show and see how the team puts together a range of machines that has grown to challenge some of the biggest in the industry

60 International Forest Industries | AUGUST/SEPTEMBER 2013

sunny week in Sweden for the IFI team started in the small industrial town of Rottne, where the namesake company was founded. Escorted by Assembly Production Manager Per Lundkvist, the IFI team was toured around the Rottne factory, which produces almost all its own components for the expert team to put together individual machines for its clients. We have since leaned that construction of new engineering and training facilities at Rottne has also begun. The construction will be divided into stages and is expected to be completed next Spring. The current construction phase will deliver premises that will include laboratories for experimental work covering 1,650 m2 and a 750 m2 training area. The next phase is will expand the spare parts department to 2,450 m2. “We have already started the construction building,” Chief Executive Rolf Andersson said. “The training building starts a little later. “It’s a big investment for us at about SEK45 million including the spare parts department. We have chosen the construction company Granflo Construction from Aseda, which offered the best solution for us.” Today, Rottne has 235 employees situated mainly in Rottne but also spread

across the Swedish towns of Lenhovda and Stensele where the company’s other manufacturing facilities are found. Annual turnover is some SEK450 million with about 50% of Rottne machines exported to mainland Europe, Russia, North America and Australia. Today, this private Swedish group challenges major international corporations such as John Deere, Komatsu, and Finnish rival Ponsse for market share, but that wasn’t always the case – Rottne has grown from humble beginnings.

Rolf Andersson, outside the new factory

COMPANY FOCUS – ROTTNE

Rottne employees hold crucial knowledge of the industry that is needed for optimal machine production The story starts almost 60 years ago with company founder, Börje Karlsson, who used to help with his father’s timber business based in the forest in Löpanäs, just outside of Rottne. Transport by horse had been done away with in favour of a tractor but loading was still a manual affair and so Karlsson began designing ways of using the idling tractor to speed up the process. Out of these designs came Rottne’s first loader – a basic construction consisting of a pair of plough components, a piece of timber, a winch fitted to the takeoff as well as a piece of wire and a pair of timber tongs. The loader worked well and soon enough Karlsson had an offer to buy the machine, which he accepted, and went on designing and manufacturing more machines to meet the fledgling local demand for the product.

Publisher David Lansdowne and Editor Chris Cann inspect some of the Rottne components under the guidance of Assembly Production Manager Per Lundkvist

It’s a big investment for us at about SEK45 million including the spare parts department Rottne Chief Executive, Rolf Andersson on the factory expansion

Karlsson bought himself a new workshop and his machines were soon being exported to Denmark and Norway, to name a few fairly proximal international markets, and within 10 years there were units on their way to Tanzania and Chile – quite a feat in export logistics for a small, private, Scandinavian outfit in the 1960s. Then, in 1968, Rottne delivered its first modern forwarder – the Blondin (Blonde). The Blondin was the company’s first complete forestry machine and became a

best seller because of its relatively small size, versatility, loading ability and handling. By 1977, Karlsson had added the Editor Chris Cann is taken through the latest 770-processor to the Rottne features of the Rottne cab range and for the first time the company was able to boast a desire to lead equipment design complete equipment range. In for the forestry sector wherever 1985, the Blondin was finally possible. The H-series harvester retired and replaced by the series was a testament to that and innovative Rapid model, which proved to be a leading seller was a purpose-built forestry amongst harvesting contractors. machine that no longer relied on a At Elmia this year, the tradition tractor base. of leading technology has reached Throughout the 1990s and into a new level with the launch of two the last decade, Rottne specific developments that got consistently proved that it was a visitors and competitors alike company not simply satisfied with talking about Rottne – the H21D competing but was a genuine harvester and the second generation of Comfort Line system, which were covered in the previous edition of IFI. IFI

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HIGH PROFILE

Andersson and the team with customers at Elmia this year

Making a difference International Forest Industries Editor Chris Cann shared a bench on the Rottne stand at Elmia with Managing Director Rolf Andersson and discussed his life in the forestry, the emergence of Rottne as an international power, and the importance of a holiday Rolf Andersson, Rottne Managing Director

62 International Forest Industries | AUGUST/SEPTEMBER 2013

people higher up at Rottne to be recruited internally into the sales department, where I specialised in domestic sales at first. I became sales manager for Sweden Rolf Andersson: My father had always and then fairly quickly took on the role of worked in the forest industries and our senior sales specialist for Scandinavia. family had always owned forests so it was And this is all within Rottne. I was elected a fairly natural progression for me to move to the role of President in 2005 and have into the forestry business, too. I also went been working hard to fulfil the demands of to the one of Sweden’s specialist forestry that role ever since – schools so you could and I hope I’ve been say that it was a reasonable successful. decision to go into I’m still very interested I was enjoying the forestry but is was a sales position but I had very, very natural and in forestry machines, been working within easy decision to make – particularly product Rottne for a long time it was a family business development when the opportunity but a passion as well. came up and I knew I was working as a everyone including forwarder operator for a people who I had been involved with Swedish entrepreneur who had many during my time as an operator instructor contracts at any one time but in 1978 I left who were now various stages within the that employer and went to Rottne, which group. When I was asked one day if I at the time needed a demonstration would like the job, I thought: ‘why not?’. operator. Because of my apparent skills as I think what I brought to the role was a a driver they said that I was a valuable genuine understanding of the forest and acquisition for them – so that’s where it forestry machine – have been working started with Rottne. I also worked as an with forestry machines in the forest my instructor with the next generation of whole professional life. There isn’t a forestry operators. I obviously impressed

International Forest Industries: How did you get started in the forestry sector?

IFI_PG60-64_Company Focus Rottne_HR 29/08/2013 14:14 Page 63

HIGH PROFILE

We’re active in Scandinavia, America and Canada as well as throughout Western and Eastern Europe and have other possibilities to get bigger

specific skills set I’d say suited me to the job but I knew how the forestry industry works and I knew most of the people who I would be managing. I knew where the company needed to go, I knew the people who would be crucial in taking it there, and I had the relationships and the understanding of the industry to ensure that Rottne was able to move successfully in that direction. For that matter, I also knew all the competitors against which Rottne would be facing off and most of the people who worked with them so I was confident of not only moving Rottne forward in line with what the company objectives had been but I was also certain that I knew how to position ourselves best within our industry in terms of the opposition. Through time in the industry, I understood the company, I understood the business, I understood our competitors and I knew what the customer wanted.

I’m still very interested in forestry machines, particularly product development. I contribute a great deal to product development and very much enjoy working alongside our design team to come up with ideas that are going to actually make a difference to contractors.

IFI: What’s been your greatest achievement for Rottne? RA: Things have changed so much over the time I have been at the head of the group that the challenges and achievements have varied greatly. I think the period over which we launched the H series of harvesters was an extremely important moment for the company because it was the transition from the range we used to have into the current range that we have today. That was a whole new generation of harvester that we delivered that had grown from the H20 through to the H8 – it was particularly satisfying because of

Andersson and Hennberg enjoy a rare moment of peace on the busy Rottne stand with colleagues

Andersson with Export Manager, Jan Hennberg, who has been instrumental in establishing Rottne at the top of the market

The last 40 years has been an incredible period of development for the forestry sector, which I believe has surpassed machine development in most other industries

my close involvement with the design of these machines and then of course the reception from the market, which really appreciated what we had done. What’s particularly significant is the size of the company that we are, or were. You are comparing what is essentially a small family company coming from Rottne, the small village you visited, to multinationals like John Deere, Komatsu and Caterpillar – there are of course small differences between the machines but our machine program I feel is as good as their machine program. So we are very proud as a small company to be able to compete with companies of that size. We feel that it is a genuine achievement to be able to compete with these

guys on an international scale and it is largely down to the development of the H series of harvesters and also the F series of forwarders, which was essentially their equivalent.

IFI: What kind of focus do you have on international markets as opposed to domestic markets? RA: We are of course well known on the international market with many different products – we’re active in Scandinavia, America and Canada as well as throughout Western and Eastern Europe and have other possibilities to get bigger. It is important for us to find the right distributors and sales contacts because the after sales service and the aftermarket

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HIGH PROFILE

products have to follow the standards of our machines – you cannot just go into a country, introduce the product and start selling machines, you have to be able to build up a reputation for the complete service. That is what is crucial for operators who lose money when machines are off the stand being serviced or repaired. It’s no good having a dealer who can’t assist with parts and servicing. The machine program we have today is suitable for many markets. We have machines that are suited to the Asian market, particularly on the forward side of the business. They are working with track-based machines a lot in those markets so our forwarders are very well suited to fit those specific needs. On the harvester side of things at the moment, probably not so much for Asia. On the forwarder side, our machines are also very suited to the South American market and also anywhere that is working heavily through plantation forests – we have a great range for almost any need. Our harvesters meanwhile, have the ability to compete with the trackbased machines that currently dominate South America, mainly because of the heads we can accommodate on our harvesters. The trackbased machines can take possibly three rows as they move forward, whereas we can work down the centre of one row and take three rows to the right and three rows to the left – we take seven rows. The investment on one of our machines is of course higher but the productivity is much higher and fuel consumption is far lower, too.

IFI: how long does it take it take to establish a dealer in a new market? RA: It can take anything from three months up to a year to just to find a dealer and secure a contract and then it takes another year of training, education, service technician induction and general meetings to prepare them to not only sell but provide that crucial aftersales service.

IFI: What products are you working on now? RA: The H21D is an extremely importantly product for us right now. It’s an eight wheeler machines and it’s the new generation of forestry machine. We’re no taking orders just yet but the prototype is operational is will be test driven for a year at least out in the forest and then we have to make modifications before we can be comfortable making sales. Maybe in a year or a year-and-a-half it will be on the market.

IFI: What have been the greatest advancements in machine technology over your time in the industry? RA: There have been revolutionary developments from the 1970s until today. The

greatest advances have been in the electronics and computers through the communication with the mill and between the head and the carrier. There have also been huge leaps forward in machine hydraulics and operator comfort, which has really been the focus of many manufacturers in the past few years in particular. It’s been unbelievable what’s happened over those 40 years. It’s been an incredible period of development for the forestry sector, which I believe has surpassed machine development in most other industries. In the 1970s, some operations were still operating with handsaws. Today, operators study for a long time in order to begin working on a modern harvester. Development will continue. The focus will continue to be on operator comfort and saving fuel. In that sense I think that hybrid vehicles could be the next big innovation that has a material effect on the businesses of forestry contractors.

IFI: Would you consider working with an engine manufacturer to produce a hybrid engine for your machines? RA: I can’t see any problem whatsoever in working with an established engine manufacturer to develop a hybrid solution. We are already working closely with John Deere on engine production and they of course want to sell more engines and so for them it makes sense, also. If another engine manufacturer approached us to work on something like then we of course would also be free to move down a similar line with them. We have plenty of options when it comes to making something happen on the hybrid front, but that is just one avenue that we can look.

IFI: Is hybrid technology something you’re actively pursuing at the moment? RA: Yes and no. We have made initial investigations and are looking at the possibilities that are in front of us but are yet to actually commit to full R&D on a hybrid solution.

IFI: What’s your favourite airport? RA: I travel a lot and enjoy Copenhagen airport the most I think, in Europe at least. Scandinavians tend to like Copenhagen but it just seems to move efficiently.

IFI: And your least favourite? RA: St Petersburg. There’s too much bureaucracy. You seem to spend hours in immigration and queuing up for customs and security. The queues are long and they move slowly. That said, it’s an improvement on the situation in the 1970s under the Soviet Union – it was even worse We actually just had a major order from Russia from a company called DLK, which bought 17 machines including various models

64 International Forest Industries | AUGUST/SEPTEMBER 2013

It’s extremely important for those at the head of the company in stressful positions to ensure they take some time off to recharge otherwise the performance starts to suffer

of forwarder and harvesters that we delivered over six months. It’s quite competitive for business in Russia and having established ourselves here to a certain degree it is very important that we cement that foundation through our dealer. This unfortunately will mean more trips through St Petersburg airport! The Russian market is an important market for us but it’s also a very tricky market. It’s a big place and you must not only be able to deliver your machines to customers but also supply the aftersales service that contractors need to be successful. This is a huge challenge for all suppliers in Russia.

IFI: When do you get a chance to get away on vacation? RA: Infrequently. Sometimes when I take a break I prefer to be at home but, if I do choose to travel, I usually like to do some downhill skiing in Austria. I normally go with family and friends and spend about a week out there. I also do a bit of hunting at home. I was born there on the farm and have always enjoyed hunting. It’s extremely important for those at the head of the company in stressful positions to ensure they take some time off to recharge otherwise the performance starts to suffer. It is not always easy to do when there are so many demands on your time but I try to take a full month off each year away from Rottne. IFI

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ELMIA WOOD REVIEW – PART TWO

CEJN’s eSafe – THE NEW GENERATION COUPLING eSafe is an innovative and patented safety coupling offering the highest flow combined with a low pressure drop. In addition eSafe has a low connecting force, compact and easy to grip design making it the natural choice when choosing a safety product with top of the line features. By using eSafe, you’re guaranteed a reliable product for years to come.

The most compact and manoeuvrable PrimeTech model The new PT-175 features the same technology and components as the other models of the PrimeTech range (the 275 hp PT-300, the 415 hp PT-400 and the powerful 600 hp PT-600). It encompasses a series of improved features and solutions that turn it into an even more advanced vehicle.

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EPSILONâ&#x20AC;&#x2122;s EPSCAB is the only cabin available with an air-suspended seat, which brings together with the seat heating unprecedented standard. EPSILON cabins are being painted in a 3-stage-system comprising KTL prime coat, powder coating and white top painting of the whole cabin with exception of the door, which is being painted in black. From now on their cabins can be ordered with a hydraulic servo control, instead of the conventional manual control.

Bosch Rexroth Bosch Rexroth launches heavy duty motor range for the forestry industry Rexroth MCR-W: 60 % higher radial load capacity compared to standard radial piston motors The Bosch Rexroth MCR range of radial piston motors has been specifically developed for a number of forestry vehicle applications including feed rollers, rotator heads, wheel and slew drives. Central to the range is the new MCR-W type designed for forestry harvester head feed roller applications.

Bosch Rexroth New series 40 of the A11VO high pressure axial piston unit for especially demanding applications Forestry machines: up to 10 % faster control behaviour of implement hydraulics. - Fast control behaviour for more dynamic implement hydraulics - Efficiency increased to up to 93 % - Optimised housing structure reduces noise emissions

Cummins presented Ultra-low emission engines for forestry use at Elmia Wood Cummins Inc. displayed key products from its EU Stage IV / EPA Tier 4 range, 37-503 kW (49-675 hp), at Elmia Wood for the first time. The QSF2.8, QSB4.5 and QSB6.7 provide a reliable, ultra-low emission product ready to work in key forestry applications.

66 International Forest Industries | AUGUST/SEPTEMBER 2013

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New Trailer-mounted HYPRO processor HYPRO has developed a new processor model which was displayed at ElmiaWood. It is a trailer-mounted HYPRO 755 processor without crane and winch that will fit on almost any forest trailer on the market.

Komatsu Forest unveiled three new simulators for harvesters, forwarders and forestry excavators. The new simulators provide more lifelike operation with improved graphics and more realistic physics. Simulators are an important part of training forest machine operators and Komatsu Forestâ&#x20AC;&#x2122;s simulators are widely used for training purposes worldwide. The new simulators are more training-based than previous versions, and now focus more on operating technique and work planning to further improve methodology training.

Dasa takes Bucking to a new level with Forester Dasa Control Systems AB launched a new generation system for optimised logging at ElmiaWood 2013. The new generation system has been named Forester, which associates it with sustainable forest management and optimum yield for forestry stakeholders. Forester is the 6th generation system from Dasa and draws on the company's experiences from previous generation systems. Development was undertaken in close cooperation with leading manufacturers of harvesters, forwarders and logging units.

AUGUST/SEPTEMBER 2013 | International Forest Industries 67

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NMS displayed their new range of 7-14 ton tractor trailers with sets of cranes between 5,2 – 8,3 meters. Also, a brand new 14 ton forwarder NMS FW1408A was introduced for the first time in Sweden. The forwarder has one of the most durable chassis and maintenancefree bearings available in the market. NMS says that every single product they sell is the creation of their customers.

Nokian Forest King TRS LS-2 tyre for skidders Nokian Heavy Tyres displayed the new 35.5L-32 Nokian Forest King TRS LS-2 tyre to complement the tyre selection for skidder equipment. – So far, we have been lacking a tyre of the size 35.5L-32. It is a common size, however, and they are especially sold to North and South America, says Sales Manager Vesa Sampakoski from Nokian Heavy Tyres. The new tyre is five inches wider than before, and when the diameter is 2,010 millimeters, the total weight amounts to nearly 600 kilograms’. The load-bearing capacity is high, meaning that the tyre meets today’s standards. Size is not the only new feature of the latest Forest King. The tread pattern has been developed for even higher traction.

The forwarder that sets a new standard for 20-ton forwarders At this year’s Elmia Wood, Komatsu Forest displayed its new forwarder, the Komatsu 895, for the first time before a wide international audience. Komatsu claim the 895 is the market’s first “proper” 20-ton forwarder with powerful chassis construction and power train. Komatsu 895 sets a new standard for the really big forwarders. The new power train has been developed and adapted for 20-ton forwarders. The engine delivers high performance with good handling characteristics combined with effective combustion for low fuel consumption. The transmission system automatically adapts to the load, slopes, and obstacles. The transmission can further increase traction when the going gets tough and speed drops. This enables the forwarder to climb obstacles with considerable ease compared to machines with the previous generation of hydrostatic transmission systems.

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Doppstadt Truck-mounted DH 810 precision chipper New compact precision chipper for processing logs with diameters up to 600 mm. The revolving upper carriage makes it very flexible for feeding and discharge. Truckmounted operation and transport. DH 810 L is energy efficient and service friendly. Used for an efficient production of wood chips.The large feed-in roller and the aggressive apron feeder guarantee the in-feed of all kinds and shapes of wood without difficulty. The size of the final product can be regulated. Weight (ton) app. 31 ton including truck Engine/Drive 360 kW Chipping drum width 85 cm Chipping drum Ø 100 cm Chipping knives 4 pcs. Speed 610 rpm Max log Ø 60 cm

Hiab, part of Cargotec Corporation, showcased its new forestry crane – the Hiab Loglift 108S – at the Elmia Wood fair. The crane, developed on the basis of customers’ feedback, was designed around the favourite features of both the Hiab Jonsered and the Hiab Loglift forestry crane ranges. In addition to the new crane, Hiab presented a selection of other forestry cranes that offer world-class durability, performance, and weight-to-capacity ratio.

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IFI_PG70_71 Cutting Edge_01 29/08/2013 14:19 Page 70

Konecranes CXT Biomass is a fully automated crane for handling different kinds of biomass in a continuous process in demanding surroundings

CUTTING EDGE

The Konecranes CXT biomass crane is smart and compact Konecranes’ CXT Biomass is a fully automated crane for handling different kinds of biomass. The crane’s optimised biomass software enables the power plants to be efficiently operated 24/7

ne of the big advantages with the CXT Biomass crane is that it’s more compact than a traditional loader conveyor-based solution, which increases the fuel storage capacity of a plant. The crane is also quieter than conveyor-based solutions and also reduces dust and fuel emissions. The crane is equipped with a range of Smart Features such as slack rope prevention, which prevents the grab from tilting and hoist ropes from slacking. Sway control is a handy feature that dramatically reduces the average work cycle time by keeping the load stable and on its intended path. Another smart function that increases productivity is Extended Speed Range (ESR) that allows the hoist to run at a higher-thannominal rated hoisting speed with empty grab, which significantly reduces cycle times.

service through the company’s global service network, with almost 420,000 pieces of equipment under maintenance contracts. The maintenance services range from mandatory inspections to preventive or fullservice maintenance and operation partnerships. As a matter of fact, Konecranes can offer specialised maintenance and modernization services for all types of industrial cranes. In addition to inspections and preventive maintenance programs, Konecranes also offers advanced diagnostics services, such as the

Fully automated crane combined with top maintenance The main task for the CXT biomass crane is to handle fuels, such as peat, wood chips or communal waste. In short, the crane receives biomass from a tipping area and lifts it to a storage area or directly to a feeding hopper. The crane can also feed biomass from the storage area to the hopper. Since biomass handling in automated plants is one of the most challenging tasks for heavyduty cranes, operating in a continuous process, maintenance is a key factor to keep the process running. Konecranes can offer comprehensive maintenance

Konecranes CXT Biomass is a fully automated crane for handling different kinds of biomass in a continuous process in demanding surroundings

Crane Reliability Survey, an engineering assessment of the current condition and future maintenance needs of cranes; RailQ runway assessment, as well as RopeQ wire rope analysis. These analyses provide customers with valuable information that can be used as a guide when planning future actions.

into the limited space inside the building. It also needed to be extremely reliable and adaptive, as it was intended to be the sole device to feed the boiler. The new boiler started to deliver steam on its target date, and the client has been very satisfied with the performance of the feeding system.

Tailored crane solutions to meet customer needs

Key facts

The CXT’s compact design, high capacity and Smart Features were the main reasons it has been chosen by Scaldis, a specialist in handling bulk for continuous process industries. The company recently delivered a turnkey system for biomass handling in a big factory in France that diversified its steam production that is traditionally based on gas, which required a new biomass boiler. In close co-operation with Konecranes the feeding system was customized to meet the factory’s exact needs. The crane needed not only to have sufficient capacity to provide the boiler’s consumption flow, but also to fit

Crane classifications Hoist for process use in duty class ISO M6 (FEM 3 m) or M7 (FEM 4 m) Crane classification

Bridge travelling machinery class

Crane designed for ambient temperature Positioning accuracy for axial movements Weighing accuracy

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from -10˚C up to +50˚C ± 100 mm

±5% (as an option ±2% is available)

• Typical conditions in biomass halls, like dust and high humidity, have been taken into account by having heaters for motors and inverters as standard features, rail sweeps in end carriages, and upgraded protection class for key components, like motors • Electrical cubicles are usually placed on the bridge, but the control panel is brought to floor level for easy and ergonomic access. Optionally, cubicles can be placed in a customer’s control room • The optimal size of a hydraulic clamshell grab is selected based on a customer’s process needs. The orange peel grab is also available • The CXT Biomass crane is available in duty class M6 up to 10 t and M7 up to 8 t. If heavier loads or a higher duty class is needed, Konecranes has the GL crane series, which has proved its performance in various WTE plants around the world. www.konecranes.co.uk

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CUTTING EDGE

Deere parts on-the-move

ohn Deere has released a new mobile version of its parts Web site – www.jdparts.deere.com – designed to utilise smartphone technology to help loggers manage their operations more efficiently. The new user-friendly site allows loggers to access critical equipment parts information with their handheld devices, from nearly any location. “Our customers are usually in the woods, at job sites far from their offices, and they can’t wait to

get back to their desks to order critical parts,” Shawn Riley, Manager of Parts Marketing Operations, said. “They asked us for a mobile version of the parts site so they could place orders when and where they needed to, so we responded.” Like the desktop version of the site, the new mobile version allows customers to quickly access parts information, view pricing, availability and order parts online. Customers can search by parts

catalogue, model number, part number, or keyword to locate the appropriate parts and attachments. Designed for any web-enabled mobile phone or tablet, the mobile version is easy to navigate and use. It also features a dealer locations link to find the closest John Deere dealer to make purchase and pickup faster and easier. To access the full capabilities of the site, customers will need to establish accounts through their John Deere dealers. For more

information, contact your local John Deere dealer or visit www.JohnDeere.com

Rexoroth advances suit forestry machines down to the ground The new series 40 of the Rexoroth A11VO high pressure axial piston unit has been designed especially for demanding applications. Forestry machines place extremely high demands on the dynamics and stability of the implement hydraulics in order to achieve maximum productivity. In the first heavy-duty series applications, the new A11VO axial piston variable pump of series 40 from Rexroth demonstrates an up to ten percent faster control behavior with an efficiency increased to up to 93%. The fast control behaviour of the A11VO series 40 increases the dynamics of the implement hydraulics and simultaneously stabilises load-sensing systems.

As a result, forestry machines spontaneously respond to operating commands even under high loads or with fast load changes, including cases where multiple consumers need to be supplied at once. This increases the working speed and efficiency, e.g., for harvester heads. Within the scope of the fundamental redesign of the pump, the Rexroth developers have increased the efficiency to up to 93% and thereby achieve a value greater than other comparable pumps. Through the compact dimensions, manufacturers of forestry machines can integrate more power in tight installation spaces. A likewise newly developed

sealing system reliably prevents leakage through a significant reduction in the high-pressure sealing points. Rexroth achieves the higher control dynamics through an optimised adjustment system based on the proven plain bearing support of the swashplate. Numerous hydraulic and electric controllers, some of which can be controlled remotely, facilitate highly efficient power and pressure controls as well as stroke limiting and load-sensing functions. An optimised housing structure of the high-pressure pump also reduces noise emissions considerably: in pressuringholding operation, the operating noise is up to 3 dB(A) lower than

is typical for other comparable pumps. This reduces the work associated with reducing noise to the legal emission limits for the manufacturers of forestry machinery. The AV11VO series 40 supplies the open circuits typical for forestry machines as needed at a nominal pressure of up to 350 bar and a maximum pressure of up to 420 bar. The universal through drive simplifies custom combinations with axial piston pumps, gear pumps and other hydraulic pumps. The A11VO is available in sizes 110, 145, 175, 210 and 280; for sizes 145 and larger, optionally with integrated charge pump (impeller) as A11VLO. www.boschrexroth.com

John Deere harvesters, FBs get an upgrade Some of John Deere’s most powerful machines, the 900KSeries tracked feller bunchers and 900KH-Series tracked harvesters, have been equipped to take on even more of the forest with the introduction of an updated boom structure and cooling system for all models. Also, the Rapid Cycle System (RCS) has been made standard on the 900K-Series tracked feller bunchers, making boom operation faster and simpler. “At John Deere, we are committed to providing loggers with improved efficiencies that make both the machine and the operator more productive” Neil Harber, John Deere Construction & Forestry Division Product Marketing Manager, said. “We’re confident our customers will

appreciate the higher productivity rates, increased uptime and lower daily operating costs with these improvements to the tracked feller bunchers and harvesters.” The new boom structure is designed to maximise logger productivity. With an additional foot of maximum reach, and 600 mm (2 ft) of additional minimum reach, the feller buncher can cover 32% more area. These improvements allow the felling head to tuck tighter to the machine to improve manoeuvrability in close quarters, as well as reach stems farther away. Similarly, the new tracked harvester boom structure has an improved cutting swath of 375 mm (1 ft 3 in), with nearly 300 mm of additional reach. The redesigned boom systems

are designed to be durable, resulting in longer machine life and added uptime. In addition, these structures have been engineered to integrate protection for hoses routed along the top of the boom. The feller buncher’s crank and link system was also redesigned and now features large steel castings, while the harvester booms were designed to accommodate through nose hydraulic hose routings. These routings guide the harvesting head hoses through the nose of the boom to the harvesting head rotator, up and out of harm’s way, and will require a Waratah harvesting head that is compatible with the through nose plumbing. John Deere is the first OEM to offer this option from the factory.

With this type of improved productivity comes a need for increased cooling capacity, which is why both the harvesters and feller bunchers boast a new cooling package design. This model upgrade includes a larger fan for 33% more airflow, larger hydraulic oil cooler and the necessary interface changes to accommodate the larger cooler. Finally, the Rapid Cycle System (RCS) for boom operation is now an option on all 900K-Series Tracked Feller Buncher models. The RCS allows the operator to control the boom, stick and felling head trajectory with a single joystick. www.JohnDeere.com

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IFI_PG72_ADV INDEX_HR 30/08/2013 13:05 Page 1

ADVERTISERS INDEX SALES OFFICES

ADVERTISERS INDEX

UK, Europe, South Africa, US East Coast

Autolog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 www.autolog.com

Microtec. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 www.microtec.eu

CONTACT: Phil Playle or David Lansdowne

Bandit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 www.banditchippers.com

Morbark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 www.morbark.com

Barko . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 www.barko.com

MPM Engineering . . . . . . . . . . . . . . . . . . . . . . 29 www.mpmeng.com

Lansdowne Media Services Ltd Tel: +44 (0)1442 877 777 Fax: +44 (0)1442 870 617 Email: phil@internationalforestindustries.com or david@internationalforestindustries.com

CONEXPO – CON /AGG . . . . . . . . . . . . . . . . . . IBC www.conexpoconagg.com CLEANFIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 www.cleanfix.org

Japan CONTACT: Yuko Ishihara Japan Advertising Communications, Inc. Star Bldg., 3-10-3 Kanda Jimbocho Chiyoda-ku, Tokyo 101-0051 Tel: 81-3-3261-4591 Fax: 81-3-3261-6126 Email: ishihara@media-jac.co.jp

Western USA (AZ, CA, NV, UT) Australia, & New Zealand CONTACT: George Roman Roy McDonald Associates, Inc 4779 Luna Ridge Court, Las Vegas NV 89129, USA Tel: +1 (702) 515 7247 Fax: +1 (702) 515 7248 Email: george@roymcdonald.com

Western USA (MT, ID, OR,WA) & Canada CONTACT: Bob Warren

Doppstadt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 www.doppstadt.com Fecon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 www.fecon.com Gilbert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 www.gilbert-tech.com John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 www.deere.com/forestry Halco Software Systems . . . . . . . . . . . . . . . . . 35 www.halcosoftware.com Hewsaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F/C www.hewsaw.com Indexator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 www.indexator.se Joescan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 www.joescan.com

MTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 www.mtu-online.com Norwood Sawmills . . . . . . . . . . . . . . . . . . . . . . 15 www.NorwoodSawmills.com Nokian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 www.nokianheavytyres.com Opticom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 www.toughestvideocamera.com Peterson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IFC www.petersoncorp.com Price Log Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 www.pricelogpro.com Rayco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 www.raycomfg.com Select Sawmill Co . . . . . . . . . . . . . . . . . . . . . . . 37 www.selectsawmill.com Tamtron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 www.tamtron.fi

Jeffrey Rader . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 www.terrasource.com

Tigercat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 www.tigercat.com

Lucidyne Technologies Inc . . . . . . . . . . . . . . . 21 www.lucidyne.com

USNR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OBC www.usnr.com

LMI Technologies . . . . . . . . . . . . . . . . . . . . . . . 25 www.lmi3D.com

WoodEXPO 2013 . . . . . . . . . . . . . . . . . . . . . . . . 34 www.woodexpo2013.com

Lansdowne Media Services Ltd Tel: +44 (0)1442 877 777 Fax: +44 (0)1442 870 617 Email: bob@internationalforestindustries.com

US Mid-West, Central & Mountain CONTACT: Kevin Lapham J.P.Media Inc 1163 E.Ogden Ave, Ste. 705-359 Naperville IL 60563, USA Tel: +1 (630) 420 9752 Fax: +1 (630) 420 9763 Email: lapham@jpmediainc.com

South America CONTACT: Ricardo Cortés Editec S.A. Avda del Cóndor 844 Of. 205, Cuidad Empresarial Huechuraba, Santiago, Chile Tel: +56 2 757 4200 Fax: +56 2 757 4201 Email: rcortes@editec.cl

Bradco Ground Shark welcomes new family member Paladin Attachments has released the Bradco Ground Shark Standard Duty Brush Cutter—the newest addition to the Ground Shark family. It builds on success of the original Ground Shark Extreme Duty Brush Cutter’s innovative deck design, aggressive machine profile and high productivity, which is the fastest selling product for Paladin in the light attachment category. This highly efficient and productive attachment clears tough ground vegetation, light to medium density brush and hardwoods up to 100 mm (4 in) in diameter. A dual pressure relief valve on the new hydraulic motor is standard, protecting against any pressure spikes that could damage the drive system. Three bi-directional blades cut in either direction to extend the operational life of the blades, minimising fleet maintenance expenses. The Standard Duty models share many of the engineering innovations incorporated into the Extreme Duty version like a heavy duty 1⁄4 in steel deck, an extremely quiet drive train, and a

72 International Forest Industries | AUGUST/SEPTEMBER 2013

shielded motor that protects it from falling debris and damage. They are available in three cutting widths: 150 cm, 180 cm, and 198 cm (60 in, 72 in, and 78 in) and in a variety of low and high flow GPM ranges to accommodate the hydraulic capabilities of various skid steer loaders. The addition of the optional pressure gauge is highly recommended because it allows the operator to maintain peak performance and prevent stalling. Optional dual steel wheel kits, mounted just behind the front safety chains on the underside of the deck, help prevent scalping. With the addition of the new Standard Duty Brush Cutter to the Ground Shark family, vegetation management professionals performing roadside maintenance, right of way clearing, site preparation, fire control, fence line maintenance, and trail maintenance now have access to the most reliable, durable, and productive brush cutters available today. www.paladinattachments.com

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