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Oldest manufacturer of laminated beams comes out on the other side stronger than ever After being urged by safety authority to improve safety conditions, Moelven put its trust in System TM.
Read the entire article on page 2.
no. 1 - 2018
The world’s largest and most advanced optimizing crosscut line sees the light of the day
Read the entire article on page 4 & 5.
System TM kicks down the door and enters a promising market formerly dominated by a competitor
Meet Envun, System TM’s first European window component manufacturer to invest in an Opti-Joint V-8 finger jointing line.
Read the entire article on page 3.
From interactions to repeated transactions: What makes this leading supplier of wooden pallets loyal to System TM?
Due to its long purchase history and trust in System TM, Timpack knew exactly who to contact to add new production capacity and implement the latest manufacturing technology . Read the entire articles on page 6.
optimization of staff and wood resources
Moelven: Jan Andrén, Nikals Lindh and Thomas Gerdin, and System TM: Morten Svane and Allan Them at the test at System TM in Odder, Denmark q
Oldest manufacturer of laminated beams comes out on the other side stronger than ever After being urged by safety authority to improve safety conditions, Moelven put its trust in System TM and watched its slow-running, labor-intensive line turn into a fast-paced, optimizing Opti-Kap 5103 cross-cut line. Moelven came out better and stronger with high occupational safety and excellent wood utilization.
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Thomas Gerdin, Technical manager, Moelven:
‘‘Throughout my
entire 30 years in this industry, I’ve never been part of such a successful project like the one System TM has carried out here at Moelven.’’
In the winter of 2016, Moelven received some unfavorable news that every factory dreads hearing. The Swedish occupational safety authority urged Moelven’s factory in Töreboda to improve the safety of its finger joint machine infeed. Moelven immediately took action and opted for a System TM turnkey solution: an optimizing Opti-Kap 5103 cross-cut line. This line put an end to Moelven’s safety concerns, maximized wood yield and allowed Moelven to save a bundle on labor resources. The oldest manufacturer of laminated beams Moelven is a Scandinavian industrial group that produces building materials and systems for the construction industry. Moelven’s factory in the city of Töreboda designs and produces wooden support structures for all intents and purposes. Moelven Töreboda was established in 1919 and is the world’s oldest manufacturer of laminated beams. Cost leadership with a nice touch Moelven produces standard glued laminated beams of up to 30 meters, consisting
of finger-jointed lengths. Moelven’s beams are laminated based on two strength grades. Beams are produced by gluing various lamella layers on top of each other with strong strength grades on the outside, and less strong strength grades on the inside. This is how beams are produced at minimum cost per unit, while also taking their physical appearance into consideration. Strict about performance, flexible about approach Although scaling down production capacity may be one way of designing a less costly line, if there is something System TM never compromises on, it’s performance. The Opti-Kap 5103-line features brand-new main machines that play major roles in terms of performance: a MiCROTEC scanner and an Opti-Feed 6000 Vack automated feeding machine. It also incorporates some of Moelven’s existing minor machine parts, such as pack rollers and chain conveyors. Everything you need to know about the line In the first stage, package feeding, workpieces are transported by pack rollers and
chain conveyors into an automated vacuum feeding machine, Opti-Feed 6000 Vack. The Opti-Feed 6000 Vack handles two types of board packages, consisting of two lamella strength grades. The Opti-Feed 6000 Vack vacuum feeder takes one lamella layer at a time and places it on the conveyor chains, where stability sticks are removed. Then, workpieces are transported to a deformity scanner, a MiCROTEC Curvescan, that measures bow, twist and crook. Next, a MiCROTEC Goldeneye scanner scans for defects such as knots, splits and cracks. This data is ultimately transferred to an Opti-Kap 5103 cross-cut saw further on in the system, which uses this data to optimize woodcutting and utilize wood to the fullest. After scanning, a moisture meter determines wood moisture contents. Then, workpieces move onto the optimizing cross-cut saw, OptiKap 5103, which cuts out defects with special attention to board ends, as they must always be knot-free. Next, scrap wood is disposed, and workpieces are carried to a buffer system that feeds workpieces into Moelven’s fingerjointing machine. Moelven’s beam-builder program instructs the finger-jointing machine how to build and glue lamellas together. It also exchanges information with System TM’s line to make sure the line feeds correct workpieces into the finger-jointing machine.
MICROTEC GOLDENEYE 302 SCANNER Detection of defects and quality for cross-cut
OPTI-KAP 5103
Optimizing cross-cut saws
•
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The optimizing solution from System TM consists of the following:
OPTI-FEED 6000 VACK Automated feeding system
Automated vacuum feeding system model Opti-Feed 6000 Vack
•
Microtec curvescan
•
Microtec Goldeneye 302 Multi-Sensor Quality scanner
•
System TMs optimizing cross-cut line:
Optimizing cross-cut saw model Opti-Kap 5103
Production:
Moulding and millwork components
Wood species:
Hardwood
Number of operators:
2
System TM kicks down the door and enters a promising market formerly dominated by a competitor
Envun in front of their fingerjointing line with the polish Sales team: Pawel Mielke and Peter Simonsen q
System TM has officially opened the door to the market of finger jointing machinery for the wood window industry – an otherwise closed world where System TM’s competitor had a predominant position. Meet Envun, System TM’s first European window component manufacturer to invest in an Opti-Joint V-8 finger jointing line. Locate the weakest part, use your forward momentum, and keep your foot flat when kicking. That’s how you’d kick open a door to a house. At System TM, we use that force to kick open doors to markets. When Envun attended System TM’s Open House, Envun found the cure to boost production efficiency after experiencing underproduction of finger jointed products. Eventually, Envun became System TM’s first European window component manufacturer to invest in an Opti-Joint V-8 vertical finger jointing line. A new and well-set company While a new company like Envun may not have a rich history yet, Envun is a growing company with big aspirations for the future. Established in 2013 and headquartered in Przystajnia, Poland, Envun manufactures glued pinewood components for window manufacturers while meeting high quality standards and using high-tech production machinery. How System TM kicked down the door Envun was invited to attend System TM’s Open House in the winter of 2017 to see what System TM could put together in terms
of solutions. ’’Our Open House was money well-spent because it helped us get our message across and allowed us to show Envun that we can walk the talk’’, says Peter Simonsen”, Area Sales Manager at System TM. After experiencing underproduction of finger jointed components due to inadequate production efficiency, Envun was in search of a vertical finger jointing machine to maximize uptime and equip the company for the industry challenges ahead. Thus, Envun was on the lookout for superior machinery to secure high reliability, uptime and capacity. ‘‘We had the opportunity to meet several suppliers, but only System TM was able to meet our expectations’’, says Paweł Janoszek, CEO of Envun. With Envun’s latest investment, System TM has officially entered the market of finger jointing machinery for the wood window industry, a market known to be dominated by another supplier. How this line finger joints with high precision First, a compartment table is loaded by two operators. Then, workpiece batches are transported to a shaper, followed by a second
shaper that mills, applies glue and prepares workpieces for the vertical finger jointing process. Next, workpiece batches move down to a transfer station that feeds them one by one into the pre-alignment and pre-press station. Then, a double pressure roller presses workpieces together into components of 6 meters in length. ‘‘Having a double pressure roller is highly valuable, as our previous machine only had one roller which made our work more difficult”, says Paweł. Finally, workpieces are lifted by an elevator and stacked by an OptiStack 6000 stacking machine, providing the possibility to arrange stability sticks in between layers.
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Paweł Janoszek, Owner, Envun:
‘‘System TM fully met our expectations. The installation of the OptiJoint V-8 finger jointing line went very quickly and smoothly. System TM’s team gave us comprehensive answers to all our questions during the installation process. We can always get in touch with System TM and get quick answers if technical issues arise. Also, we highly value System TM’s remote service!’’
The results are in: here’s what Envun gained ‘‘From doubling production, to cutting labor costs, to finger jointing precisely, to utilizing wood efficiently, we are truly impressed and satisfied with this line’’, says Paweł. Its precise finger jointing and better wood utilization enables Envun to accurately cut finished products, consequently reducing waste by approximately 40%. According to Paweł, several aspects made the Opti-Joint V-8 line stand out from competitors: its high performance, solid construction, and modern design.
OPTI-JOINT V-8
Vertical finger jointing machine
OPTI-STACK 6000 Automated stacking system
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•
System TMs fingerjointing line: Production:
Window and door components
Wood species:
Softwood
The optimizing solution from System TM consists of the following: Vertical fingerjointing system OptiJoint V-8 •
Automated stacking system model Opti-Stack 6000
Number of operators:
3
Promasas production facility in Chile q
The world’s presumably advanced optimizing cr light of the day
System TM recently designed the world’s presumably largest and most advanc manufacturer. Oozing power, this line is packed with everything from a pith ec piece widths and lengths, to the ability to feed workpieces into five cross-cut s make new product developments exclusively for Promasa. >>
Max Campos Lepe, General manager, Promasa:
”We were very excited about this new line because we needed to increase our production capacity in order to process all the lumber that we produce at our sawmill. Due to the nature of our business, we also needed a line that could detect many defects at a very high speed. Now, we receieve a lot of inquires from the industry about our line because everyone is curious to see how this huge line performs on a daily basis. Just like any other project in the benninging, there were a few issues but I have to say that both System TM and Microtec were always present and providing the necesary support on-site to help us solve these issues.”
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•
Due to positive word of mouth about System TM’s products and after-sales service from colleagues in Argentina and Brazil, Promasa felt confident about assigning System TM the task to design what eventually became the world’s largest optimizing cross-cut line with five cross-cut saws, the Opti-Kap 5003 model. Although it was an honor to be given this opportunity, a few challenges were associated with building the world’s presumably largest cross-cut line. As a result, System TM had to make new technological and mechanical developments to increase production capacity more than ever and to maintain a high level of defect detection accuracy at very high speeds.
At Promasa, there are a multitude of benefits with automating manufacturing processes. Ever since the Opti-Kap 5003 line has been installed, Promasa has seen greater control and consistency of product quality, optimized yield and value, and many savings on the cost of labor. Promasa Promasa was established in Chile in 1989. Promasa is a Radiata Pine door and moulding manufacturer, supplying raw material to moulding and door producers for the American market. Promasa seeks to expand market dominance in the door and moulding industries using its passion for excellence, responsibility towards the environment, and commitment to workplace safety and employee development. Never underestimate the power of word of mouth In these interconnected days, how customers feel about companies and what they tell others about them can influence reve-
MICROTEC GOLDENEYE 702 SCANNER WITH X-RAY
nues and profits just as much. While on the lookout for the right supplier, Promasa came across System TM due to good WOM (Word of Mouth) from Argentinian and Brazilian colleagues, who expressed their satisfaction with System TM’s machinery and after-sales service. Eventually, WOM played a pivotal role in Promasa’s decision to invest in the world’s presumably largest cross-cut line, a System TM Opti-Kap 5003 line. From imagination to creation While searching for the perfect cross-cut line back in 2014, Promasa did not wish to settle for anything less than a cross-cut line with high-capacity scanning for uneven workpiece widths and lengths, which could process workpieces at 400 meters per minute. A pith locator for eccentric pith positions was also on Promasa’s wish list. System set out to fulfill Promasa’s wishes by incorporating a MiCROTEC mini CT scanner for pith eccentricity measurement into the Opti-Kap 5003 line. The mini CT scanner
OPTI-KAP 5003
Optimizing cross-cut saws
Detection of defects and quality for cross-cut
>>
The optimizing solution from System TM consists of the following:
In 2014, Promasa embarked on its journey to find the perfect cross-cut line with strict performance demands in mind. Some of Promasa’s demands included high-capacity production, scanning uneven workpiece lengths and widths, and pith eccentricity localization.
Microtec Goldeneye 702 MultiSensor Quality scanner including
System TMs optimizing solution line:
X-ray
Production:
Components
Wood species:
Softwood/Hardwood
5 x optimizing cross-cut saws model Opti-Kap 5003
Number of operators:
4
bly largest and most cross-cut line sees the
High-quality production examples from Promasa q
advanced optimizing cross-cut line for Promasa, a Chilean door and moulding pith eccentricity locator, to a high-tech scanner that processes uneven workss-cut saws all at once. To create such an enormous line, System TM had to
Keeping our promises – even when it gets hard Designing and manufacturing the world’s largest cross-cut line may seem like a task that is easily accomplished. Or is it? Designing the Opti-Kap 5003 line with one scanner for five saws was an exciting yet uneasy task, as it entailed expanding production capacity to a degree never accomplished before by System TM. As a result, this called for exclusive technological developments to create a cross-cut line capable of processing Promasa’s uneven widths and lengths at 400 meters per minute. Although increasing speeds may seem like the obvious solution to boosting production capacity, the secret lies in the ability to increase speeds while
maintaining the same defect detection accuracy as regular, less speedy, cross-cut lines. Also, System TM met mechanical challenges by designing the Opti-Kap 5003 line to feed workpieces into all five, optimizing cross-cut saws at high speeds without running out of wood. Here’s how the largest cross-cut line handles workpieces Workpieces enter the line from two ripsaws. At first, line operators sort incoming raw wood according to its quality. Next, workpieces are trimmed and bisected by trim saws if needed. Then, workpieces automatically move by means of a lifting wheel and are eventually lifted to the second floor where the cross-cut line is situated. Workpieces are then examined by the MiCROTEC scanning equipment – first, a mini CT scanner that locates eccentric pith positions and defects, followed by a visual scanner that scans for other defects. Upon scanning, workpieces are ready to enter two distribution systems featuring two sweepers. The sweepers brush
off workpieces before they enter two crosscut systems – cross-cut system 1 with three optimizing cross-cut saws and cross-cut system 2 with two optimizing cross-cut saws (5 in total). Altogether, the cross-cut saws chop up to 750 finger-joint ready components per minute. Cross-cut system 1 and 2 each have 35 sweepers which help sort finger-joint ready components into different qualities, widths and lengths. Finally, a re-rip option is available for workpieces with defects on the sides. High workflow automation, high savings The Opti-Kap 5003 line replaced a major part of Promasa’s manual labor with automation. Thanks to this line, Promasa’s cost savings from automation have been realized by producing a higher value product through optimum wood utilization and remanufacturing.
q
is a pith locator with 3 X-ray sources that produces 3D images of eccentric pith positions. As for boosting production capacity to get more done in less time, that’s where the Opti-Kap 5103 line’s five cross-cut saws play a major role.
High-quality production examples from Promasa
5
Timpack headquarters in Hamilton, New Zealand q
From interactions to repeated transactions: What makes this leading supplier of wooden pallets loyal to System TM? Maintaining a superior market position as a leading timber packaging company involves staying on top of rapid technological developments in manufacturing. Due to its long purchase history and trust in System TM, Timpack knew exactly who to contact to add new production capacity and implement the latest manufacturing technology.
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Jason Togia, General Manager, Timpack:
“I have been working with Per and System TM for many years and have visited their state of the art factory in Odder, Denmark where I have found their product, service and people to be reliable, forward thinking, responsive, great to work with and of a very high standard. We hope to continue this relationship on other projects for years to come and would recommend you talk with System TM for high quality optimizing saws.”
It is plainly constructed of raw wood and nails. Most people never give it a second glance, but consider for a moment the modest wood pallet. It is so ubiquitous that it is everything but invisible. The wood pallet is one of the workhorses of our global economy and an essential platform for transporting goods from warehouses to store shelves. At Timpack, the wood pallet is the very foundation of the company’s success. System TM has been there along the way, frequently supplying Timpack with high performance machinery for pallet and bin production. So, what is the key ingredient to Timpack’s continuous loyalty? The answer lies in the hightrust relationship that exists between Timpack and System TM – a relationship based on a shared ability to neutralize the effects of geographic distances. In 2016, Timpack reached out to System TM and System TM’s New Zealand dealer, Southern Cross Engineering, to replace its former System TM manual crayon-marking line and expand production capacity. As a
result, Timpack invested in an optimizing Opti-Kap 5103 cross cut line that incorporated a MiCROTEC GE301 scanner. Since then, the company has gained tremendous production capacity, economies of scale, and maximum utilization of wood. What keeps Timpack coming back for more? Trust leads to successful business transactions which are repeated for many years. In international business, B2B relationships require high commitment, trust and dependability because big things happen across large distances. ‘‘We have established a high-trust relationship with Timpack by getting to know Alan Walters (CEO) and Jason Togia (General Manager) on a personal level, setting the right expectations, aligning offerings with Timpack’s goals, sharing knowledge, and visiting Timpack on a regular basis”, says Per Jensen, Area Sales Manager at System TM. Timpack Industries Ltd. Providing the dairy, horticulture, meat and manufacturing industries with total pallet and bin solutions since 1984, Timpack is at
the cutting edge of timber based packaging. Located in Hamilton, New Zealand, Timpack employs over 200 staff. Timpack is committed to the latest technology, supplying its customers with industry standard pallets or custom designed pallets. At Timpack, automated machinery is used to produce highquality products that meet strict criteria for hygiene, robustness and load bearing A recipe for top-notch production The optimizing Opti-Kap 5103 cross cut line is a replacement of Timpack’s former manual crayon-marking line. Not only does this line automate and accelerate production, it also frees Timpack from the monotonous work involved in manual crayon-marking. Initially, package feeding takes place by means of a tilt hoist. Then, a separator makes sure Radiata Pine workpieces are separated and organized before arriving at the subsequent conveyor. As workpieces move along the conveyor, they enter the MiCROTEC GE301 scanner. Then, scan results are transferred to an optimizing software program which calculates optimal cutting positions and instructs the Opti-Kap 5103 cross-cut saw how to cut workpieces with maximum wood utilization. Eventually, workpieces leave the cross cut line to be sorted to different locations for further processing, such as a moulder and/or a band re-saw.
OPTI-KAP 5103
Optimizing cross-cut saws
MOULDER
MICROTEC GOLDENEYE 302 SCANNER
Detection of defects and quality for cross-cut
>>
The optimizing cross-cut line from System TM consists of the following:
OPTI-FEED 6000
Automated feeding system
•
Automated feeding system OptiFeed 6000
•
Microtec Goldeneye 302 MultiSensor Quality scanner
•
System TM’s optimizing cross-cut line:
Optimizing cross-cut saws model Opti-Kap 5103
•
Moulder
Production:
Pallet manufacturer
Wood species:
Softwood
Number of operators:
6
Production-boosting cross cut line takes the pain out of manual crayon-marking at Tumu
TUMU team: Andrew Cranswick and Reece Fergusson together with System TM team: Kristian Florup laursen,Tommy Sørensen and Per Jensen at System TM headquarters in Odder, Denmark q
When it comes to manufacturing prowess, mastering the science of streamlined, efficient pallet and bin production is a top priority at Tumu. Investing in a new, optimizing Opti-Kap 3003 cross cut line featuring a MiCROTEC GE301 scanner helps secure increased production capacity and saves Tumu the hassle of manual crayon-marking. They’ve carried your fruits and vegetables, your wines and spirits, your pelts and hides. Almost every product on the consumer or industrial market has spent time sitting on a pallet or in a bin. These humble pallets and bins allow easy forklift access to goods and expedite the loading and unloading of freight worldwide. In 2016, Tumu expanded its facilities to meet increasing demand and boost production capacity. Thus, Tumu turned to System TM for new pallet production machinery. Together with its dealer in New Zealand, Southern Cross Engineering, System TM has repeatedly equipped Tumu with machinery for more than 6 years as a result of a hightrust relationship. ‘‘Trust is very important, especially when you’re dealing with two companies on opposite ends of the world. Despite the physical distance between us, we always manage to create excellent results by collaborating closely on production line layouts”, says Per Jensen, Area Sales Manager at System TM.
A closer look at Tumu Timbers Tumu Timbers has been processing and supplying timber packaging products since the 1980’s. Located in Hastings, New Zealand, some of Tumu’s products include standard and custom designed timber bins and pallets for the domestic and export markets. Particularly, Tumu has experience with the apple and kiwifruit industries, produce growers, food processors, packaging companies, meat processors and the wine industry. How Tumu excelled at boosting production Tumu has been equipped with System TM automated stackers and cross-cut lines since 2012. In the days before automated manufacturing, Tumu used to mark workpieces manually – a highly time-consuming process. Ever since Tumu started automating manufacturing processes, workpieces have been processed with much better wood utilization due to the optimizing software program incorporated in System TM’s cross-cut lines. In addition, automation has liberated Tumu’s production line operators from repetitive and tedious work, as well as decreased the need
for production line operators. In 2016, Tumu underwent facility expansions and an increasing need for production capacity a perfect time for Tumu to upgrade production machinery and invest in a new Opti-Kap 3003 cross-cut line.
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Andrew Cranswick, Operations Manager, Tumu:
‘‘We continue to work with System TM due to their commitment to building solutions that overcome our production challenges. They stand behind what they sell and ensure that our expectations are exceeded.’’
An effective method for maximizing wood utilization The first stage in the optimizing Opti-Kap 3003 cross-cut line is represented by package feeding. Freshly cut wood is transported by chain conveyors into an automated vacuum feeding machine, Opti-Feed 6000 Vack, which arranges workpieces on conveyor chains before they enter a MiCROTEC GE301 scanner. Then, scan results are passed on to an optimizing software program that calculates optimal cutting positions and instructs the subsequent Opti-Kap 3003 cross-cut saw how to cut workpieces with maximum wood utilization. An air sweeper sweeps short lengths and two automatic sweepers transport workpieces onto two band re-saws to split them. Finally, workpieces are stacked by means of an automated stacker, Opti-Stack 3000.
OPTI-STACK 3000 Automated stacking system
OPTI-KAP 3003
Optimizing cross-cut saw
MICROTEC GOLDENEYE 301 SCANNER Detection of defects and quality for cross-cut
>> OPTI-FEED 6000 VACK Automated feeding system
The optimizing cross-cut line from System TM consists of the following: •
Automated vacuum feeding system Model Opti-Feed 6000 Vack
•
Sensor Quality scanner
System TM’s optimizing cross-cut line: Production:
Pallet manufacturer
Wood species:
Softwood
Microtec Goldeneye 301 Multi-
•
Optimizing cross-cut saws model Opti-Kap 3003
•
Number of operators:
Automated stacking system model Opti-Stack 3000
7
Visit
System
TM
at
the
following
exhibitions:
IWF 2018, Atlanta, USA,
August 22 – 25, 2018
Trä & Teknik 2018, Göteborg, Sweden,
August 28 - 31, 2018
www.systemtm.com
no. 1 - 2018
System TM, a leading global provider of customized solutions for the solid wood industry System TM offers a wide range of automated material handling systems designed to give you excellent production capacity, maximum wood utilization and reduced labor costs. Our material handling systems are defined as standard system solutions and fully customized solutions designed to meet diverse customer needs.
Opti-Feed
Automated feeding systems
Opti-Kap
Optimizing cross-cut saws
Opti-Stack
Automated stacking systems
Opti-Joint
Automated finger jointing systems
Opti-Solution Customized system solutions
System TM’s prime focus is optimization of staff and wood resources. We streamline production processes and ensure maximum profitability from resource optimization. At System TM, we advise customers by drawing on our technical expertise and knowledge to design the best solution that fits your needs. Please visit our website at www.systemtm.com to find a material handling solution that fits your production requirements.
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