INSIDER Millwide
THE MAGAZINE FROM USNR | ISSUE #2 - 2013
NEW MILL IN RUSSIA Maltat Group selects USNR for its major new venture
NEW RETREAD PRESS IN MEXICO Global giant Continental Tire installs new retread press from USNR
SUPPLYING THE WORLD’S EQUIPMENT USNR proves its broad range of capabilities with projects around the globe
Millwide
INSIDER ISSUE #2 - 2013
SUBSCRIPTIONS Tel.: 250.833.3028 subscriptions@usnr.com EDITOR Colleen Schonheiter colleen.schonheiter@usnr.com CONTRIBUTING EDITOR Sonia Perrine sonia.perrine@usnr.com
USNR’s international presence Tradeshow season is upon us and the first really big show of 2013 is Ligna taking place at Hanover, Germany May 6 – 10. In this issue we bring you stories of USNR’s expanding presence across the globe.
USNR PARTS & SERVICE 7/24 Service: 800.BUY.USNR Tel.: 360.225.8267 Fax: 360.225.7146 Mon. - Fri. 5:00 am - 5:00 pm PT www.usnr.com
The Maltat Group of Companies is embarking on an ambitious new venture and chose USNR to supply a modern sawmill for the Krasnoyarskiy Krai region of Russia. The mill’s new primary breakdown line will be shor t on space but big on recovery. Installation of the complete mill complex is well underway, with commissioning slated for later this year. USNR has made its mark in the international wood processing arena. With new greenfield sawmills, complete plywood and panel lines, and major press projects, we’re fuelling the fires in today’s global wood processing market revolution. Read about the fruits of some of our international labors. When Continental Tire, a world-leading tire producer, wanted to expand its retread tire business it selected USNR’s Pathex retread press to do the job. Today the equipment and par ts delivered to run your operation may very well arrive on truck tires using retreads made with USNR’s press. USNR is proud to have developed successful par tnerships with several international agents in the wood processing realm. Read about these trusted and talented groups who work on the front lines in their respective regions of the globe.
USNR LOCATIONS Woodland, WA Headquar ters 360.225.8267 Parksville, BC
Eugene, OR
250.954.1566
541.485.7127
Plessisville, QC
Jacksonville, FL
819.362.8768
904.354.2301
Salmon Arm, BC
Painesville, OH
250.832.7116
440.352.9381
© 2013, U.S. Natural Resources, Inc. All rights reserved. POSTMASTER: Send address changes to 1981 Schurman Way, Woodland, WA 98674. Canada Post: Return Undeliverable Canadian Addresses to: USNR c/o Colleen Schonheiter,
We are excited to take this quick look back and see all we’ve accomplished, and how we’ve made our mark on the world stage. And we look forward to continuing to move our products, services and exper tise to new frontiers. Sincerely, Colleen Schonheiter Editor
3550 - 45th Street Southeast, Salmon Arm, BC V1E 4N2
Stacker rollcase
Radius back unscrambler
Side chipper
Vertical bin sorter
Cambio ring debarker
USNR sawmill installation underway in Russia Winning a major greenfield sawmill project in Russia has resulted in significant product development innovations for USNR. Renowned as a leading supplier of the world’s broadest range of wood processing systems, USNR was challenged to develop a new 4-sided canting solution for the primary breakdown process. As requested, this new primary breakdown line will be short on space but big on recovery. Installation of the complete mill complex is well underway, with commissioning slated for later this year. ISSUE 2 - 2013 | Millwide INSIDER
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USNR SUPPLIES MAJOR NEW SAWMILL OPERATION IN RUSSIA The Maltat Group of Companies is embarking on an ambitious new venture to bring jobs and prosperity to the Krasnoyarskiy Krai region of Russia, with an end goal to produce materials for housing. As announced in 2012, USNR is proud to have been selected to design and manufacture a complete new sawmill for the site at Yeniseisky, located in Siberia, Russia. The supply will consist of a debarking line; primary breakdown line with canter, quad arbor sawbox and vertical arbor gang; green and dry trim/sort/stack lines; and residual processing equipment. Maltat has a secured log supply in the region comprised of 50% pine and 50% larch, with average log diameters of 24 cm and lengths of 3.0 to 6.2 m. This new sawmill is the first phase of the larger development project, and is expected to begin
operation in late 2013. Once commissioned, the mill is projected to have an annual capacity in the range of 550,000 m3, and eventually growing to 1 million m3 of logs. The operation will employ 150 people in two shifts.
“There are no mills available in this territory that can be compared to the one being established by us in terms of the volumes and the degree of automation.”
Largest of its kind in the region Alexander Nikolayevich, chair of Maltat Group Board of Directors, is quoted as saying, “There are no mills available in this territory that can be compared to the one being established by us in terms of the volumes and the degree of automation. I hope that in the near future our mill will find itself among the industry leaders.” He went on to explain that this project is one phase of a major development project for the Angara-Yenisei region, where the main industry to date has been mining. The goal of the development is to increase employment opportunities and revenues for the region, while taking advantage of the transportation and energy infrastructure that is currently utilized by the mining industry.
MALTAT SAWMILL PROCESS FLOW DIAGRAM (red arrows depict flow) STEP FEEDER – SINGULATE LOGS LOG DECK – ACCUMULATE LOGS
GREEN MILL PROCESS LOADER
STEP FEEDER – SINGULATE LOGS
LOG DECK #1 DEEP PILE
SCAN
ROTATE
SAWLINE DEBARKER
LOG DECK #2 SINGLE LAYER
CHIP SIDES
CHIP TOP & BOTTOM
PROFILE #1
CHIPS
CHIPS
CHIPS
BARK
HOG TO BOILER
LENGTH / WIDTH / THICKNESS SENSING
FUEL
14 BIN SORTER
TRIM END 2
STICK / DUNNAGE PLACER STACKER
TO DRYER TRIM BLOCKS
DRY MILL PROCESS TILT HOIST – SEPARATE BOARDS FROM PACKS
LUMBER GRADING STATIONS
TRIM END 1
TRIM END 2
LENGTH / WIDTH / THICKNESS SENSING 36 SLING SORTER
FROM DRYER STACKER LUMBER PACKAGE STRAPPER PACKAGE WRAP STATION PACKAGE OUTFEED
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Loaded containers arrive at the site. In addition to USNR’s supply which includes a complete sawmill operation for processing logs into lumber, the broad scope of the development to be completed by 2015 will encompass log sorting, lumber drying and biomass production. The complex sits on 45.5 hectares with production targeted primarily for the export market.
PROFILE #2
CHIPS
SEPARATE SIDE BOARDS
SAW
SAWDUST
PROFILE
CHIPS
SAW
SAWDUST
TRIM END 1
Primary breakdown equipment is placed.
Unloading equipment
TRIM BLOCKS SAWDUST TO FIREWOOD
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Maltat installation team management: (left to right) Sergey Peicov, Evgeniy Kulagin, Alexey Kulagin
Vertical bin sorter
USNR’s supply
Project status
► ►Green trim/sort/stack line: radius back
► ►Debarking line: Cambio 600 debarker; log infeed
unscramblers; Newtronic lug loaders; Valley trimmer; length/width/thickness sensing system; 14 vertical bin pusher lug sorter; bellcrank stacker with pre-staging and boxing load; stick and dunnage placers; package outfeed; WinTally™ sorter management system
decks; step feeders; operator cab ► ►Primary log breakdown: auto rotation conveyor;
scanning system; centering vertical skewing log infeed; side head conical chipping canter with facing saws; vertical feedroll modules; top & bottom conical chipping canter with facing saws; profilers; Quad Arbor Saw Box; sideboard dispatch and transport; vertical single arbor gang saw; MillExpert™ Log Optimizer system
► ►Dry trim/sort/stack line: tilt hoist; radius back
unscramblers; stick collection system; Newtronic lug loader; Valley trimmer; 3-zone grading line with automatic board turners; length/width/ thickness sensing system; grade printer; 36 bin pusher lug sling sorter; bellcrank stacker; lath placer; package outfeed; strapper; WinTally™ sorter management system ► ►Residual processing: rotary hog with infeeds
from debarker, log line, green and dry trim lines ► ►Filing room package ► ►ControlLogix PLC control systems for USNR-
supplied equipment Horizontal profiler
USNR PRIMARY BREAKDOWN LINE
B
D
E
A
C A LOG ROTATING INFEED
6
B SIDE CHIPPERS
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USNR’s project manager, Hank Vaandering, explains the status of the project. “Over the past year Maltat has been busy remodeling existing building structures and preparing the foundation for the new building to accommodate the processing equipment.” He went on to explain that, in addition to the processing equipment USNR is supplying, Maltat has ordered kilns, boilers and a log sorting line from other vendors. To date, much of the sub-steel for the USNR supply has been erected. The green sorter bins are fully installed, with approximately 80% of the rest of the green trim/ sort/stack line now in place. About 30% of the main log breakdown line has been set, the most recent component being the positioning infeed system. Maltat’s current goal is to have the green trim/ sort/stack line and the main log breakdown lines set in place and ready for alignment by the middle of May. USNR personnel have been on site supervising the installation and placement of the equipment. Maltat is hopeful that commissioning of the entire complex will proceed in the latter half of this year. USNR is honored to be a major contributor to this important development for this region, and to the wood processing industry in Russia.
C TOP & BOTTOM CHIPPERS
D PROFILER MODULE #1
E PROFILER MODULE #2
G
F F QUAD ARBOR SAWBOX
G PROFILER MODULE
H VERTICAL ARBOR GANGSAW
H
Millwide. Worldwide.
The profiling advantage USNR is well known throughout North America for providing exceptional primary breakdown lines with a wealth of options available. And USNR has also designed primary lines for many other regions. In any case profiling is a common element that is prevalent in our latest designs.
WHY AND HOW TO ADD PROFILING TO YOUR PRIMARY LINE USNR has invested decades perfecting our primary line offerings, with hundreds of global installations in a wide range of configurations to meet specific requirements. Now we take a closer look at the profilers that are streamlining the breakdown process.
The Why Many mills today are adding profiling capabilities to their upstream processes to reduce or even eliminate the need for an edger. As an example, when profiling is integrated with USNR’s Quad Arbor Saw Box (QASB), boards emerge from the machine center ready for trimming, sorting and drying. Add USNR’s powerful MillExpert optimization, and this machine center is fast and accurate for maximum value and throughput. Profiling can be used with any size of log. Depending on log size and the mill’s market the outside flitch may contain 1-2 boards, and the inner may also contain 1-2 boards. If the mill’s edger is already at capacity but the mill wants to increase
its saw line production, a profiler will alleviate the demand on the edger and allow the mill to increase its throughput. Profilers can typically accommodate a production speed of up to 600 fpm. Sawing is usually what slows down production speed; profiling cuts away some of the material so the sawblades don’t have as great a depth of cut, and this allows the line to run faster.
The How Today’s profilers can be oriented along a vertical or horizontal axis, so they can provide profiling for both the side boards and the top and bottom boards in the stack. Typically profilers have been mounted on a carriage but USNR has also provided profiling heads mounted on the front of a vertical double arbor gang. In this application the cant is profiled immediately upstream of the saws. This solution can also be offered as a retrofit provided the required space is available, but this
configuration would take up less space than a profiling module mounted on a separate carriage. With a retrofit another consideration is the upstream equipment. If the profiling heads are to be mounted on the front of the gang saws, the cant must be effectively secured before entering the cutting tools. If it is not then a powered Vertical Feedroll Module (VFM) positioned just upstream of the profiling heads is the answer, but it would require an additional amount of space. Depending on preference profiling heads can include a saw blade to produce a sawn finish, or a chipped finish where the boards will go through a downstream planer. Following are several types of profilers and layout configurations among the many that USNR can provide.
CANTER HEADS LOG LOADING CONVEYOR SCANNER
SCANNING CONVEYOR
POSITIONING INFEED
VERTICAL FEEDROLL MODULE
HORIZONTAL PROFILER SAWBOX
SCANNER
ELEVATION CHANGE
USNR PRIMARY BREAKDOWN (EXAMPLE #1): 8
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► Unsorted logs
► Scan&Set: custom solution for every log
LOG ROTATION
CHIPPER CANTER
HORIZONTAL PROFILER
HORIZONTAL SAWBOX
POCKET PROFILER
VERTICAL SHAPE SAW
Profiling alternatives
VERTICAL PROFILER
VERTICAL SHAPE SAW
Horizontal arbor profiler ► ►Right and left side carriages shift in/out and
up/down for profiling ► ►Capability to recover boards at an angle
Options to recover multiple sideboards: ► ►Stepped profile heads ► ►Separate profiling modules ► ►Independent Dual Profiler Common in the primary breakdown process, the log’s sides are first chipped to create smooth sides for securely guiding the cant through the next process. The illustrations above show a horizontal arbor profiler configuration. With USNR’s profiler the two left and two right profiling heads move in/out on their respective carriages, while the two sides can also move up/down. This readily accommodates the recovery of a board that is at an angle (eg. following the taper of the log). Downstream, sideboards will be sawn off via a bandmill or horizontal sawbox and will not require edging. This illustration (above left) depicts stepped profiling heads, which is the least expensive alternative for creating two sideboards on each side in a single operation. The steps are a fixed width,
typically creating a 2x4 and 2x6 or 2x8 on both sides. The edges of the boards have a chipped finish that will be planed in a downstream process. Another alternative (above right) is two separate profiler modules with a vertical feed module in between. This allows the greatest product flexibility, but requires more space and is more expensive. A third option is USNR’s Independent Dual Profiler. This design offers more product flexibility than stepped profiling heads, is less expensive and requires less space than separate profiler modules. (See the following page for a detailed description.) In operations where downstream boards are not planed, profiling heads can be fitted with saw blades for a sawn finish on the edges of the boards, while downstream gang saws produce a sawn finish on the board faces. Many mills choose a configuration where each profiling module skews or tilts to allow recovery of an angled board. (See the vertical arbor profiler on the following page.)
The horizontal arbor profiler consists of one right and one left side profiling module assembly, each housing two chip heads and mounted to a solid base. Each carriage shifts in/out to properly position the chip heads horizontally for the width of the log; each chip head also shifts up/down via hydraulic cylinders. The profilers remove the wane found at the corners of the four-sided cant. When a tapered log is processed boards can be recovered at an angle. As the log is being transported through the profiling heads, the heads can adjust in/out while at the same time moving up/down. This capability allows greater volume and value to be recovered from each log.
Pocket profiler ► ►Produces cants/profiles in one step
USNR commonly employs a drum-style canter head with/without pockets that can also profile the cant just upstream of the Vertical Shape Saw (VSS). (See illustration below.) To view how this works, scan the QR code at right, or go to http://www.usnr.com/media/VSS.mp4.
POCKET PROFILER
R SHARP CHAIN
VSS INFEED CONVEYOR SCANNER
► Maximum value
VERTICAL SHAPE SAW LANDING TABLE
SCANNER
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Profiling, continued... Independent Dual Profiler (IDP)
Vertical arbor profiler ► ►Right and left side carriages shift in/out
and up/down for profiling ► ►Optional skewing carriage is available to
recover angled boards The vertical arbor profiler also consists of one right side and one left side profiling module assembly, with each housing two chip heads and mounted to a solid base. The carriages each shift in or out and the chip heads shift up or down along the vertical arbor. Another option for vertical profiling is the skewing profiler. It provides the capability to skew (tilt) the profiler heads to recover an angled board as the log tapers. (Shown in the layout at the bottom of the facing page.)
► ►Four independent profiling heads for optimum
product flexibility ► ►Option for sawn finish ► ►Improved access for maintenance ► ►Minimizes build up of chips and debris
USNR’s Independent Dual Profiler offers 4 profiling heads. It processes the outer boards and inner boards independently. In this configuration each profiling head moves in or out, up or down independently of the other heads. The IDP is typically positioned immediately downstream of USNR’s VFM and upstream of a horizontal arbor gang saw or USNR’s QASB. Alternatively each profiling head can be fitted with a
saw blade for a sawn finish on the boards. The VFM provides maximum stability as the piece is being transferred out of typically a chipper canter, and maintains accurate positioning for further chipping or sawing. The rolls are powered to drive the cant forward. The IDP employs 2 main carriages as well as sub-carriages to provide its flexible positioning. The 2 main carriages shift out for easy maintenance and knife changes. All carriage actuation along both horizontal and vertical axes is via hydraulic linear positioner cylinders. Chips are discharged through bottom ducting.
POSITIONING ROLLS TURNING ROLLS
SCANNER
TOP & BOTTOM CHIPPER SIDE CHIPPER
FLOW
USNR PRIMARY BREAKDOWN (EXAMPLE #2): 10
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► Sorted logs
► Pattern sawing: batch log breakdown
LOG ROTATION
CHIPPER CANTER
TOP & BOTTOM CHIPPER
VERTICAL PROFILER
HORIZONTAL SAWBOX
HORIZONTAL PROFILER
Chipper Profiler Module (CPM)
VERTICAL SAWBOX
VERTICAL PROFILER
VERTICAL SHAPE SAW
Profiler heads
► ►One- or 2-step configuration ► ►Available with/without attached saw blades ► ►Use double-edged, Babbitted or
aftermarket knives
► ►Machine alignment made easy ► ►Improved access for maintenance ► ►Minimizes build up of chips and debris
Recent enhancements to USNR’s primary breakdown equipment have made machine alignment much easier and provide more control over the product during processing. USNR has combined the carriages for left hand and right hand chipper canters, VFMs and profilers on left hand and right hand bases. The chipper profiler module utilizes a new mounting method that splits the chipper, VFM and profiler sections down the middle, and recombines them onto a single left base and a right base. Connecting them in this way effectively reduces the number of alignment variables by 33%, ensuring that
VERTICAL FEEDROLL MODULE VERTICAL PROFILER (skews/tilts)
the left sides and right sides of the chipper, VFM and profiler are always aligned relative to each other. This makes machine alignment much easier because now only the left and right sides need to be aligned with each other, instead of aligning three separate machine bases on each side of the machine. Splitting the modules down the middle also opens up the center line of the machine, which helps minimize the build up of chips, dust and debris. Other enhancements include improved access for knife and saw changes. USNR has installed this design in several mills with excellent results.
VERTICAL FEEDROLL MODULE HORIZONTAL SIDE BOARD SEPARATOR PROFILER
Profiler heads come in one or two step configurations, and can be supplied with or without attached saw blades. USNR’s standard knife is the TrueFlow knife that can either be a double-edged or Babbitted knife, though aftermarket knives can also be used. The USNR TrueFlow double-edge finish knife can be reground without losing the knife plane location.
The options for adding profiling to your line are nearly limitless, and it is likely USNR has designed a machine that will accomplish your goals. Contact your USNR account manager to discuss the best configuration for your application.
VERTICAL GANG SAW
SAWBOX
► Small log gaps, high throughput
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USNR’s presence is of global proportions USNR has made its mark in the international wood processing arena. With new greenfield sawmills, complete plywood and panel lines, and major press projects, we’re fuelling the fires in today’s global wood processing market revolution. Following are the fruits of some of our international labors.
MURRAY TIMBER’S PRIMARY LINE SHIFTS INTO OVERDRIVE Working with its customers to develop solutions to difficult challenges is a benchmark by which USNR measures its success. Case in point is a primary breakdown line at Murray Timber, Ballygar, Ireland. Though completely satisfied with the performance of the equipment, John Murray, the company’s production director, subsequently determined the operation would be more efficient if the line was sped up. The Murray Timber Group (MTG) realized this would help it to achieve the economies of scale necessary to broaden its market reach. With a solid investment already made in the primary end, the next step was to contact USNR to accelerate the line.
Hybrid processing blend The USNR primary breakdown line is equipped with 3D Smart TriCam™ scanning and a MillExpert™Integrated Processing Line (IPL) optimizer. USNR’s first pattern-specific optimizer, the IPL (Integrated Processing Line) allows the mill to combine the high throughput of pattern processing with the increased recovery of sets optimized for each individual log’s 3D shape. The IPL allows the basic sawing pattern to stay the same throughout a batch of logs, maintaining a consistent center cant, but allowing variations in the widths and thicknesses of 12
Millwide INSIDER | ISSUE 2 - 2013
the profiled sideboards, and also allowing sideboards to be symmetrically sacrificed (first outer pairs, and then if necessary inner pairs) as needed to achieve acceptable finished material. John Reed, senior account manager with USNR, worked with John Murray and his team on this project. Reed explains the concept. “The whole line is 110 m (343’) long with just one operator. The logs are turned three times on a straight profiling line, to manipulate the size of the piece. Once you have achieved a 4-sided cant, there is usually a bit of fiber missing from the top side once the final turn is made. When the cant is then sawn horizontally into boards there is only the one top board that needs to be trimmed, and no edger is required.”
Shifting gears The log line features three cant turners, three profiling modules and four scan zones. The scan data images and resulting optimizer solutions are relayed from station to station successively down the line, enabling just one operator to run the entire line from logs to boards. Andre LaPierre, a senior PLC programmer at USNR, was lead controls programmer when the line was initially installed. Andre was subsequently assigned to speed up the
MURRAY TIMBER, continued...
“I absolutely recommend this system, and USNR, to other mills. We get good accuracy, throughput and recovery as well as efficient manpower utilization.”
line which he accomplished in the course of one week. He explains the process. “The first step was to use trends and graphs to verify that all the complex components were in good repair and functioning correctly. The ease of this process highlighted the good maintenance practices at this mill. Next, the
scales and limits in the feed drives and main PLC were increased to allow for faster speeds. Lastly, I began the process of incrementally speeding up the machine and verifying that all the components remained functioning correctly. As the machine runs faster and faster it is doing things it has never done before, so it is necessary to just watch to make sure everything is still timed right.” Andre went on to explain that the complicating factor is that it is a pattern-fed machine, so it is necessary to see every pattern go through the machine to verify it is running correctly. He noted the result. “We corrected some issues the mill had identified, and increased the feed speed from 103 meters per minute (mpm) to 115 mpm. That’s more than a 10% increase. At the end of my trip the system ran just shy of 22 logs per minute.” Andre further commented, “Two impressive things about this project was its scale and the ability to draw such a short log gap. Thirdly, the MTG team makes it run with 98% uptime. The line just runs, and runs, and runs.”
A single operator runs the entire line.
100% satisfaction John Murray commented on the project’s succcess, “Andre LaPierre was key in accomplishing the increase in speed. Without Andre it would not have been completed in a week and as successfully.” When the line was commissioned, John Murray spoke very positively about the equipment’s performance and USNR’s handling of the project. “I absolutely recommend this system, and USNR, to other mills. This USNR equipment is extremely strong and resilient. We get good accuracy, throughput and recovery as well as efficient manpower utilization.” And after several years of operation John says he is still, “100% satisfied with both the equipment and level of support provided by USNR.“
AR CONVEYOR
SINGLE LENGTH INFEED
Scan this QR code with your smart phone to go to see this line in operation or go to the Murray Timber website: www.mtg.ie
CANT TURNER
CANTER
CANTER
CANT TURNER
FLOW
SCANNER
BOARD SEPARATOR
PROFILER
SCANNER
LOG TURNER
CANT TURNER
SCANNER
VERSA GANG
FLOW
PROFILER
SAWBOX
SCANNER
BOARD SEPARATOR
SPLITTER SAW
DROP LANDING TABLE TUNNEL
PROFILER FLOW
ISSUE 2 - 2013 | Millwide INSIDER 13
BSW TIMBER IMPROVES THROUGHPUT AND RECOVERY trimmer performance and highest valued trim decisions. MillExpert optimization coupled with ControlLogix controls delivers it all. The board line features the high-speed Quad Cam boardfeeder. The Quad Cam’s simple design offers
Choosing to work with USNR led the BSW Timber’s Carlisle Sawmill to invest in capital improvements that have removed bottlenecks in the production process. The result has been increased piece counts and better recovery. BSW Timber is the largest sawmilling group in Great Britain, with five mills based in the UK and a mill in Latvia. Carlisle is the newest mill in the UK group, with annual output in the range of 200,000m3. The mill processes Sitka spruce harvested from within a 100 mile radius of the mill, with logs ranging in size from 14-40 cm in diameter. The mill typically runs two shifts per day, 5 days per week, but has curtailed that slightly through the winter period due to slowing markets. Products coming from the Carlisle mill include lumber for the construction industry, fencing and heat treated timber for pallets, and are sold entirely within the UK. With bottlenecks created as a result of outdated lug loading and PLC system, the Carlisle mill first set out to update its controls and optimization technology on its board trim line in 2007, and then its deal trim line in 2008. USNR was selected as vendor of choice. The board line produces products 16-47mm thick, 75-225mm wide, and up to 4.8m long; the deal line produces 19-150mm thick, 50250mm wide and up to 4.8m long material. The trim lines were designed to be nearly identical except for a few variables related to size of products processed. Each line consists of spiral 14
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rollcases fed by existing unscramblers. The board line was given a high-speed Quad Cam boardfeeder, trimmer optimizer and 6-stage trimmer fence. The deal line received an accelerating lug feeder, trimmer optimizer and 4-stage fence. Both lines were updated with the latest Allen-Bradley ControlLogix controls technology for the existing trimmer and sorter equipment. The trimmer optimizers are both transverse MillExpert™ optimizers with Smart TriCam™ laser scanning. The high-performance 3D Smart TriCam sensors provide unparalleled data density and accuracy. Controlling trimmer flow, actuating trim decisions, full coverage scanning and high-speed processing are keys to achieving the optimum
The first day of scheduled start up the mill operated at 70% production, and 100% on the second day.
smooth, low maintenance performance. Low impact handling means less damage to the lumber and less wear and tear on machinery. The board line operates at a rate of 120 lugs per minute (LPM), and 100 LPM on the deal line. The Carlisle optimization personnel travelled to USNR’s facility in Parksville, BC for training on the MillExpert system. Further training was conducted at the mill site. The board line was started up in December 2007 with the deal line following in December 2008. Key personnel involved with the projects were Alistair Sommerville, the Carlisle mill manager, and Nigel Patrickson, who served as the mill’s project manager and electrical specialist. They worked closely with the USNR team throughout the projects to ensure each step progressed smoothly. A direct result of this cohesive team approach to the projects, the first day of scheduled start up the mill operated at 70% production, and 100% on the second day. Extensive performance testing set by the mill and USNR was done and approved by the mill within a week of start up for each line. Along with the new technology, BSW Carlisle received USNR’s software maintenance agreement (SMA) that allows for regular updates of USNR optimization software. This ensures that USNR customer mills will operate with the latest software that is available. With its new optimization systems and controls technologies, the Carlisle mill is seeing improved productivity and increased recovery. It is well positioned to continue to meet and exceed the needs of its customers with high-quality products.
Scan this QR code with your smart phone to go to the BSW Timber website or go to: www.bsw.co.uk
WESPINE GOES GRADERLESS WITH LHG’S VISION
“We have managed our transition to graderless operation on our planer mill line with no market disruption due to quality at all. We could not have achieved these things without the benefit of the strong working relationship that we have developed with the USNR team.”
significantly. And since implementing and tuning the LHG’s new vision
the situation to around 1 mm accuracy on knot dimensions, and has enabled a reduction in conservatism in grade boundaries resulting in a further increase in grade recoveries.” He went on to explain that even before tuning of all grading parameters was complete, WESPINE started to realize significant improvements in grade and value recovery. Schaffner noted that the implementation of vision technology yielded a 4% improvement in value recovery in the planer mill over what it was previously achieving with LHG’s earlier technology applications.
system the need for human grading has been eliminated completely.
Choosing partners
After first implementing the LHG X-ray and laser profile scanning technology, WESPINE reduced its reliance on human graders
WESPINE Industries at Dardanup, Australia, began its journey toward automated grading in June 2005 when it implemented USNR’s Lineal High Grader (LHG), outfitted with laser profile and X-ray scanning capability. At that time, vision scanning technology and the ability to process and classify the data for automated grading was still maturing. The company opted to apply laser profile and X-ray technologies as an interim solution. This yielded the capability to grade for geometric characteristics, to size knots utilizing X-ray density data, and to interface to the mill’s existing HCLT strength evaluation system. The mill had been using HCLT technology for about 20 years for strength grading, but required four graders on each shift to grade for knots. WESPINE’s Business Development Manager Richard Schaffner, explains, “The X-ray system proved to be very reliable at detecting the presence of knots. Trials on WESPINE wood run through the LHG showed that the system could be tuned to produce a very reasonable estimate of the knots utilizing X-ray technology. The only system available on the market at the time employing X-ray was the LHG.” Schaffner continued, “The LHG team was willing to work with WESPINE’s electronic systems
people to integrate data from the HCLT with the X-ray and laser profile data, and to accommodate all of this in the trim solution.” He went on, “By mid-2007 we were convinced of the merits of laser vision capability. Then came the global financial crisis. With the passing of the worst of this, the time was right to go ahead with implementing laser vision, which is what we did in 2010.” The scope of the vision upgrade project included completely new computer hardware, a new software version release, four vision sensors for 4-sided scanning, and LED lighting.
Schaffner made these final comments. “We take our obligation to comply with the Australian grading standards very seriously, and believe that a cautious and thorough approach to changing our grading technology is justified. Our customers have grown used to WESPINE’s product quality and it would reflect negatively in the market if the quality was to suddenly drop. We have managed our transition to graderless operation on our planer mill line with no market disruption due to quality at all. We could not have achieved these things without the benefit of the strong working relationship that we have developed with the USNR team.”
Proof positive Schaffner explains the benefit WESPINE is achieving with this investment. “Prior to the vision implementation the LHG system was not able to detect and classify resin pockets and streaks, or splits and checks. The upgrade to the LHG incorporating laser vision has enabled automatic detection and classification of these defects, and value recovery has improved significantly.” He continued, “A further benefit has been a significant improvement in knot sizing and positioning accuracy. Laser vision has improved
Scan this QR code with your smart phone to go to the WESPINE website or go to: www.wespine.com.au
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ARAUCO AUTOMATES ITS VIÑALES MILL set of continuous bins, or can be mixed with other products in a bin by defining the percentage fill for each product.
Trimmer optimizer with 3D scanning
A long and successful history led Arauco to select equipment from USNR to automate production at its refurbished Viñales site in Chile. Arauco is one of the largest forest industry enterprises in Latin America. With 14 sawmills in the region Arauco is positioned as the major wood producer in the southern hemisphere. Arauco’s Nueva Aldea industrial complex was a greenfield project with a total investment of more than $1.5 billion US. Arauco chose USNR and Solecia Ltda. (USNR’s agent in South America) to supply the trimmer/sorter/stacker line. This team offered an integrated solution with local supply of several pieces including conveyors, bin steel and installation services that added up to a cost effective solution. The trimmer line features a low profile trimmer and 48-bin sorter. Arauco was well satisfied with the result; the mill runs at its design capacity, and the trimmer optimizer line operates at 95% or greater uptime.
accommodates products for the required range of 25100mm (1-4”) thicknesses. The multi-saw lineshaft trimmer is fitted with 16 saws including opposing upper and lower precision end trim (PET) saws. This configuration allows for an increased range of PET trim lengths without the necessity of installing an additional trimmer. The 48-bin pusher-lug style sorter has two dropouts to divert lumber to a resaw. A radius back unscrambler elevates the boards to the bellcrank stacker with a magazine stick placer.
New Viñales mill project
“They understand the products and diversity of processing requirements of each of the customers in that region.”
Building on a history of successful collaboration, Arauco once again chose USNR and Solecia to supply its latest sawmill trimmer/sorter/stacker line, this time adding USNR’s MillExpert trimmer optimization to the mix.
Controls features
Mechanical supply The center and edge boards are discharged to a landing table to be deep-piled, and then fed to a radius back unscrambler and Revolver lug loader. The Revolver is outfitted with a rotating overhead holddown; with the mill’s product mix this design 16
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Arauco selected the WinTally™ system for its sorter management and production reporting. WinTally features real-time and long term database storage of board and package details with flexible reporting capabilities. The product-based system allows for the set up of new products at any time. Each product can be assigned to a unique bin, a
The MillExpert Trimmer optimizer analyzes scanned lumber in 3D. It is configured for top and bottom scanning utilizing Chroma+scan 3150 sensors for 8.5mm (0.33”) scan density. With this system no extra light curtain (or Plan View) sensor is required. This dense 3D scan data combined with high speed computer processing yields trim decisions that maximize value from each board. USNR’s Allen Larsen was in charge of managing the optimization piece of the project. “This is a mature, feature-rich solution, and the Viñales mill is taking advantage of many of the available features including random-width shop rules products combined with dimensional products, random length products, precision end-trimming, grader input, and intelligent saw selection.” He went on to explain, “One of the strengths of the MillExpert platform is its versatility in that we can easily add in support for a new sensor, and integrate it with other systems.”
Strong partners USNR’s John Jacques was responsible for overall management for the Viñales project. He appreciates the services that Solecia provides including a single point of contact for South American projects in terms of local supply of some of the materials and resources. “They understand the products and diversity of processing requirements of each of the customers in that region, and provide full integration of our equipment.” With this project Arauco continues its steady growth in South America. USNR and Solecia are pleased to have been able to combine their skills and expertise to provide new solutions to this global customer.
Scan this QR code with your smart phone to go to the Arauco website or go to: www.arauco.cl
MLT SELECTS COE LATHE LINE FROM USNR
The Coe lathe line is renowned in North America with nearly 1,200 installations. Recently USNR brought its Coe high-speed, small block lathe line technology to Russia. USNR’s Coe veneer lathe technology is renowned in North America, with the supply of lathes for the majority of LVL production. This expertise was incorporated into a state-of-the-art LVL plant for Modern Lumber Technology (MLT) of Torzhok, Russia, being touted as the most modern and efficient in Europe.
A new direction MLT company is owned by the Taleon Group, based in St-Petersburg. David Miskevich, VP Sales and Marketing for Taleon, commented “We felt there was great potential in bringing the LVL product to this market at this time to revolutionize the building process,” David and his team sought out the best equipment suppliers in Europe and North America to meet their goal of having the most modern and efficient LVL operation in Europe. David commented, “Coe was widely recognized and we felt confident that we would be satisfied with the outcome”
“The equipment is awesome. We only hope to be able to use it to its full potential.”
Miskevich also visited lathe operations in North America and was impressed with what he saw, as well as Coe’s experience having manufactured nearly 1,200 lathes.
High speed lathe line The scope of supply comprised the complete green end of the plant. The Coe M296 dual-spindle lathe, core drive and charger is the most advanced, high performance veneer peeling system in the world utilizing the BlockPLUS™ optimization scanner package, dual knife rotary clipper and a high-speed, four-bin green veneer stacking system. This highproduction line is capable of processing 18+ blocks per minute. BlockPLUS provides unmatched scan density – more than 10 times the detail of other systems. BlockPLUS accurately measures every surface detail with a precision finer than 0.3 cm (1/8”). This profile is then used by the lathe system to reduce peeling cycle time and increase recovery. Surface features can be accurately modeled, translating into a reduction in peeling cycle time of 5-7% and an increase in recovery of 2-3%. The highly accurate block profile also enables better block centering, reduced randoms, and more thorough optimization. This lathe system is capable of generating 3.2 mm softwood veneer at the rate of 32 m3/hr.
The computerized lathe charger chucks the geometrically centered block and rotates it for laser scanning while simultaneously raising and repositioning both ends to maximize veneer recovery. Then a pendulum transports it to the lathe spindles. Peel thickness adjustments can be made in increments of 0.025 mm (0.001”). Three separate peel thickness ratios allow peeling different thicknesses for roundup, sap and heart veneers. The veneer lathe can be configured to peel 1.2 to 3 m (4’ to 10’) length blocks from 10 to 90 cm (4” to 36”) in diameter. It is the only veneer lathe that can peel down to 5 cm (2”) diameter cores to get maximum veneer from the block. Servo-controlled, ruggedly designed lathe spindles, digital knife location and angle, and peripheral drives are key to providing increased veneer volume and quality. Dual or triple lathe spindles allow the lathe to apply maximum torque for large diameter logs and to increase volume and recovery by peeling down to small diameter cores.
Positive result Of the lathe equipment, David says, “The equipment is awesome. We only hope to be able to use it to its full potential.” The plant’s two main products are UltraLam-X, a cross-grain laminate that is 2-3 plys laid perpendicular, and UltraLam-R, a standard LVL panel product. Alan Knokey, VP and General Manager of USNR’s panel products division has a lot of experience dealing with large projects on a global scale. “We were very pleased to be able to contribute to this innovative new facility. Conservatively, 95% of North America’s veneer for LVL, and 85% of the world supply, is peeled on a Coe lathe. So we knew the result would be very positive.” At press time, the Taleon Group has purchased land for an OSB mill, awaiting the optimum time to launch the next big project.
Scan this QR code with your smart phone to go to the MLT website or go to: www.ultralam.com/uk
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The new ContiLifeCycle plant at Morelia, Mexico
Continental Tire
Retreading the world’s tires When this world-leading tire company wanted to expand its retread tire business it selected USNR’s Pathex retread press to do the job. Today the equipment and parts delivered to run your operation may very well arrive on truck tires using retreads made with USNR’s press. Did you know USNR is in the tire business? When USNR acquired the assets of Coe Manufacturing it became a vendor to the tire business with the Pathex line of retread tire presses. Along with presses for rubber, Coe manufactured presses for plywood, OSB, MDF, particleboard, and copper clad laminate in the Washington Iron Works and Pathex lines. In 2012 Continental Tire the Americas, LLC, Commercial Vehicle Tire Business Unit contracted with USNR for the supply of a single-sided, C-frame retread press for its new ContiLifeCycle plant located at Morelia, Mexico. With an increasing demand for retreaded truck tires throughout the Americas, the company saw an opportunity to increase the throughput of this operation. Scan this QR code with your smart phone to view a video about Continental Tire the Americas.
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Continental Tire plans to expand the capacity of this 3100-square-meter plant to meet production levels of more than 1 million flat retreads annually by 2015. The company’s Commercial Vehicle Tire Business Unit offers a wide range of truck, bus, and commercial specialty tires. Continental tires are manufactured at 22 locations worldwide, with annual sales in 2012 of over 9.7 billion euros. The new ContiLifeCycle plant in Morelia supplies Continental’s network of retread licensees throughout the Americas, including 9 locations in the US, 10 throughout Mexico, 2 each in Brazil and Ecuador, and 1 each in Canada and Chile. The ContiLifeCycle retread products are manufactured to have the same tread designs and engineering features as new Continental truck tires. The Continental Tire company had previously built a good working relationship with USNR through support for the Morelia plant’s existing Pathex retread press.
The retread press process Utilizing heat and pressure, the press converts six uncured (green) extruded lengths of rubber, each nominally 11 m (36’) long, into vulcanized truck tire retread material. The press consists of nine frames with seven 11 m (36’) long hot plates (platens) that are heated with thermal oil. Continental Tire’s proprietary design retread molds are mounted on the USNR mold mounting plates, which in turn are clamped on top of the hot plates. Six spools of the green rubber (also called green stick) are loaded manually onto USNR’s tread stock uncoiler. The uncoiler consists of a framework with six shafts mounted in bearings on one end. The ends of the green sticks are loaded manually from the rolls and into the clamps on the load boom. The clamps close and the boom moves horizontally along its guide and down the length of the press (about 11 m / 36’), while pulling the green sticks off the spools and into the press. All six press molds are loaded simultaneously. Then the clamps open and the boom swivels 90° to move the clamps out of the press to allow it to close.
Spools of the green rubber are mounted on the tread stock uncoiler while the boom awaits the PLC signal to load the press.
Once the green rubber is loaded into the press, the press begins to close at high speed using a high volume, low pressure pump to raise the nine 35.5 cm (14”) diameter hydraulic cylinders. When contact is made in all daylights (openings) between the rubber and the hot plate above the rubber, the hydraulic power unit switches to the low volume, high pressure pump to continue closing the press, squeezing the rubber into the molds. The press remains closed while the heat is allowed to transfer into the rubber.
At prescribed intervals the press opens slightly to allow gases to escape from the curing rubber. This slight opening and degassing is called “bumping”. The number of bumps per press cycle will vary by customer requirement, rubber compounding, and the thickness of the rubber, and is often 5 or 6 times. When the rubber is fully cured the press decompresses, slowly bleeding oil from the hydraulic cylinders. Once the hydraulic pressure is low enough, the press opens quickly. The load/
Nine hydraulic cylinders actuate closing the press daylights (openings).
The boom clamps firmly grasp the ends of the green rubber.
unload boom is swiveled 90° into the press, the ends of the cured treads are manually pulled from the molds, folded over themselves 180°, and placed into the clamps on the load/unload boom, the clamps close, and the boom moves approximately 22 m (72’), pulling the rubber out of the molds, down the length of the press and onto the cooling conveyors. On the cooling conveyors the rubber is allowed to cool and is then processed further by ancillary equipment.
Retreads cool on the cooling conveyors.
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USNR’s Dave Davis (above, third from left) trains plant workers in press maintenance.
USNR equipment supply The USNR supply consists of a complete pressing system including press, tread stock uncoiler, load/ unload boom and clamps, guide system for load/ unload boom, cooling conveyors, mold plates (for mounting the molds), mold clamps, hydraulic power unit, hydraulic piping, heating piping, bumping system, PLC and controls program. The Allen-Bradley ControlLogix PLC control system includes a semi-automatic, pushbutton control for
operating the press, and a PanelView screen operator interface. The system offers the capability to bump progressively (by varying hydraulic pressure at any time during the cycle), if desired. The press is also equipped with a manual system for opening the press in the event of a power failure. The simultaneous bumping system includes a set of mobile platen stops mounted to the press frame which move into position after the press closes. The effect is to limit the travel of each platen during the bump cycle to 1.25 cm (1/2”). When the press bumps, the lower bolster is allowed to move down approximately 8.9 cm (3-1/2”) which allows each of the openings to open a maximum of 1.25 cm (1/2”) via gravity.
Press expertise The Pathex press line includes a double C-frame press, which is basically two C-frame presses situated back-to-back. The advantage of a double C-frame press is that two completely independent pressing systems can share a common frame and installation, saving on capital cost and factory floor space, and increasing throughput. The Pathex line also includes a window frame press, tractor track press, snowmobile track press, vacuum enclosed copper clad laminate press, and a custom laboratory press for the development of a licensed engineered wood product developed from pulp wood.
Project success
A vacuum press for copper clad laminate.
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The press installation and commissioning was completed in early 2013. USNR personnel who were primarily involved in the project include Pete Volk, account manager; Joe Chaykowsky, project
manager; Clint Spangler, mechanical engineer; Stephane Demers, hydraulic power unit design; Ed Simmons, controls, who along with Dave Davis did the installation and commissioning. Davis was also responsible for training the plant personnel. This new press has now taken its place in the plant, turning out retreads that are helping to deliver goods to all corners of the globe. Continental Tire is pleased with the throughput and quality of the material coming from the plant with this latest investment. And USNR is proud to partner with this world leader, and to count this achievement among the many in which it has played a role for processing operations around the globe.
APA 2012 INNOVATION AWARD
WINNER
Millwide. Worldwide.
USNR’s global partners Supplementing our well-trained, professional personnel, USNR has developed associations with agents in several areas of the globe. They are well versed in the unique challenges that face wood processors in their respective regions. Our international business associations help us serve our customers near and far.
SKOOKUM IN NEW ZEALAND / AUSTRALIA The alliance between USNR and Skookum Technology, based in Auckland, New Zealand (NZ), has resulted in an abundance of successful projects and satisfied customers in and around NZ, Australia and the Pacific Islands. Skookum Technology was created in the early 1990’s when John McLachlan, formerly of Kockums (NZ) Ltd. (now part of USNR), was approached by USNR to act as an agent in that region. The relationship took off and business flourished. Geoff Strang came on board in 2001, and today John and Geoff are the company’s major shareholders. Skookum’s principle focus is the wood processing industry, offering new and used equipment sales, aftermarket support and spare parts, supplemented by project engineering and management services. It sells and supports the full range of USNR products, as well as used equipment from Scandinavia and North America. Success has allowed Skookum to expand from its headquarters in NZ to incorporate a sales team and workshop / warehouse in Kalangadoo, South Australia.
A marriage of talents In recent years the alliance has honed its flair for combining skills and capabilities to bring about the best system solutions for wood processing in the area, from log infeed through solid wood, plywood and panel equipment manufacturing. Two major fairly recent trimmer / sorter / stacker 22
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line projects include a green mill installation for Nelson Forests’ Kaituna mill at Marlborough, NZ, and a dry mill installation for Carter Holt Harvey at Whangarei, NZ. Other NZ projects undertaken by the duo have included an edger optimizer and curve sawing gang installation and upgrade at Pukepine Sawmills, Te Puke; a green mill trimline upgrade at Carter Holt Harvey, Whangarei; planer mill infeed and software upgrades for a MillExpert/LASAR carriage optimizer and log sorter optimizer at Red Stag Timber, Rotorua; CAE chipper head upgrade at Tenon, Taupo; several MillExpert carriage optimizers with LASAR scanning; and MillExpert optimization on a small log line and board edger at Kiwi Lumber, Masterton. Geoff Strang is intimately involved with most of the projects taken on by USNR and Skookum, and expressed how well the two organizations complement each other in the marketplace. “USNR offers a diverse range of leading technology mechanical and optimisation products that are ideally suited to the NZ / Australian sawmilling industry. As well, USNR has a huge depth of experience in sales, engineering, product support, scanning optimisation, and more, which is readily available to assist and support Skookum and the customer base in this region.” And Skookum brings local support in the way of technical expertise and spare parts, and local engineering, project management and fabrication to supplement USNR’s new equipment orders.
SKOOKUM, continued...
“Both teams understand and respect each other’s strengths and areas of expertise, and that goes a long way toward creating successful projects and satisfied customers.”
Unique capabilities Geoff went on to outline Skookum’s unique capabilities. “Skookum endeavors to offer the best solution for customers’ requirements, often including a combination of new and used equipment and technology. Our preference is to be involved from the feasibility stage of a project, to ensure that all options have been explored and evaluated.” He said that in some cases used equipment can be utilized, but this needs to be carefully evaluated and all costs analyzed to ensure it is truly the best solution for the customer’s application. “We are big on building relationships based on trust and success, the same basis that exists in our relationship with USNR.” He also explained that Skookum prefers to get the customers actively involved in all projects, and this enhances buy in during commissioning when it is time for the customer to take the reins. John Reed, USNR senior account manager, has worked with Skookum Technology for many years and a multitude of projects. He says, “I’ve known John McLachlan since the Kockums CanCar days, in the 1980’s. I have worked on many projects with the Skookum team over the years and we have an extremely good working relationship. Both teams (USNR and Skookum) understand and respect each other’s strengths and areas of expertise, and that goes a long way toward creating successful projects and satisfied customers.” The USNR / Skookum alliance has resulted in many millions of dollars in projects. Customers are benefitting by the widest range of products and technologies available worldwide, local project management and engineering expertise, local support and parts warehousing, and by two solid, reliable suppliers committed to creating the best solutions to match customer requirements. For more information please visit: www.skookum.co.nz.
Nelson Forests’ Kaituna mill, New Zealand, during construction.
Skookum’s responsibility frequently involves creative solutions to get the job done, on time and on budget. The company arranged the transport of a used bin sorter that required barging the equipment up the coast of New Zealand until it could be trucked the final leg of the trip to its new home.
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SOLECIA S.A. IN SOUTH AMERICA
Above, Arauco’s Viñales mill during construction. Left, Urufor S.A. in Uruguay.
► ►Maderas Prensadas Cholguán S.A., Chile, 1999:
120 LPM sawmill, output of 280,000 m3/year ► ►Berneck, Brazil, 2005: 120 LPM sawmill, output of
330,000 m3/year USNR and Solecia S.A. of Concepción, Chile have enjoyed a successful business relationship since the early 1990’s. With many millions of dollars worth of projects to their credit, this alliance has benefited both organizations and a host of wood processing operations throughout South America. Solecia has been in business for more than 60 years, originally founded and owned by an association of Swedish exporters. During the 1970’s the company turned its focus to the forest and woodworking industries representing several Scandinavian and European manufacturers of equipment and technology. Solecia’s ownership has since changed hands but remains privately held. Today Solecia represents several Swedish, German, and Canadian companies in South America including manufacturers of log handling and sawmilling equipment, controls and optimization systems, chippers, screens, biomass production and
“Solecia has found in USNR the right partners to develop and maintain good relationships with our customers, resulting in the reputation that we enjoy today in the market.”
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handling equipment, and sawmill tool maintenance equipment. With some of its own manufacturing as well as equipment supply from its associates, Solecia also serves the plywood sector, pulp mills, log merchandizing and more. The company employs a staff of 15 engineering and administrative personnel, and sub-contracts many additional workers for equipment and building manufacturing and installation. Solecia began its relationship with USNR’s then Newnes Machine of Salmon Arm, BC Canada aiming to round out a complete scope of supply to the lumber manufacturing industry. Newnes’ lumber handling and trimmer optimization technology was successfully introduced in South America with the project Horcones 1 for Aserraderos Arauco S.A. in 1994. Joint projects that have been undertaken include the following: ► ►Arauco S.A.: » » Horcones 1, 1994: 100 LPM sawmill with log sorting line, output of 400,000 m3/year » » Valdivia, 1995: 120 LPM sawmill, output of 420,000 m3/year » » Horcones 2, 1997: 120 LPM sawmill, output of 300,000 m3/year » » Misiones, Argentina, 1997: 120 LPM sawmill, output of 350,000 m3/year » » Nueva Aldea, 2003: 140 LPM sawmill, output of 450,000 m3/year » » Viñales, 2009: 160 LPM sawmill with anticipated output of 420,000 m3/year
► ►Urufor S.A., Uruguay, 2008: 120 LPM sawmill,
output of 300,000 m3/year Solecia’s general manager, Enrique Villalon made the following comments about his experience working with USNR. “It has been a very good and profitable relationship. Our companies share common interests as partners in the South American marketplace. Solecia has found in USNR the right partners to develop and maintain good relationships with our customers, resulting in the reputation that we enjoy today in the market.” He continued, “Today the industry in South America enjoys very high standards in terms of speeds, yields and technologies thanks to the commitment of the forest owners which are mainly large local or multi-national companies, and the solutions that suppliers like USNR provide to this market.” For more information, please visit: www.solecia.com.
HIROTA CORPORATION IN JAPAN
An alliance between USNR and Hirota Corporation was forged in 1995 with a project to supply a Shurman edger for Tachikawa Lumber. The Hirota Corporation was established in 1920 and remains a family owned and operated venture. The head office is located at Tokyo with an office and factory at Shizuoka. Hirota Corporation does business in Japan, South Korea and Taiwan; its business interests serve markets for log sorting and scanning, sawmills, pulp mills, biomass, plywood and panel, engineered wood and the pre-cut market for building construction. The company employs a staff of approximately 25, including engineers, sales, draftspeople, electricians and administration. USNR’s installations in the region are ably supported through the efforts of this professional team. Major joint projects undertaken between USNR and Hirota Corporation have served the following customers in Japan:
“The system uses 27 saws! We can get a very thin 1.25 cm (½”) board. It’s a minimum net cut of 15mm, and the saws can cut 1.6 cm (5/8”) all the way through the gang.”
► ►Chugoku Lumber, Kashima Mill,
Ibaraki-Prefecture
more flexible, and change their product mix to meet changing market demands. The edger is capable of processing up to 48 pieces per minute. The mill makes a wide variety of products to address different needs. “They’ll take four to six pieces of lower grade wood and glue them together to make a post,” Roy explained. “Then it’s wrapped in veneer from a good log, so it appears to be a very fine-grained post.” USNR International Sales Manager Toby Slagle, also commented, “They can make a solid post rather than a laminate post if they choose. They can choose to shape saw or straight saw.” He exclaimed, “The system uses 27 saws! We can get a very thin 1.25 cm (½”) board. It’s a minimum net cut of 15 mm, and the saws can cut 1.6 cm (5/8”) all the way through the gang.” Before installing the USNR gang and edger, the mill was producing 250 m3 per day running a single shift. It is now producing 450 m3 per shift. In addition, they were able to retire two of their four resaws as a result of the new gang and edger installations. For more information, please visit: www.hirotacorp.jp.
► ►Saiki Koiki Forest Association, Oita-Prefecture ► ►Yoshida Sangyo, Miyazaki-Prefecture ► ►Kuma Koiki Forest Association, Ehime-Prefecture
Yoshida Sangyo project The Yoshida sawmill is one of the largest Cedar sawmills in Japan. In 2006-2007 it underwent a major modernization, including the installation of a new USNR optimized shape sawing gang system and USNR optimized board edger system. The Hirota Corporation’s sales manager, Roy Hirota, was instrumental in the modernization of the Yoshida mill, doing the planning and layout work, as well as helping put together the sale of the USNR equipment. He commented, “This USNR equipment has some very unique features to address the specific characteristics of Japanese Cedar. Because it grows on mountain sides it often has very dramatic sweep characteristics, which can be a challenge in terms of recovery. If you try to saw it straight, you end up losing a lot of recovery, plus the lumber doesn’t have as much structural strength.” Roy continued,“But if you saw it on the curve, you’ll get longer and stronger lengths.” USNR supplied an optimized shape sawing gang, which is unique because it has no chip heads on it. USNR’s high speed board edger was provided with dual positioning pins, and both shifting saws and a bank of gang saws. This allows Yoshida to be
Above, far left, Chugoku Lumber Kashima Mill. Above, Roy Hirota (left) and Mr. Yoshida, owner of the Yoshida Sangyo mill. Below, the Yoshida Sangyo edger infeed.
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USNR EXPANDS ITS PRESENCE IN RUSSIA USNR has long recognized the importance of the Russian forest products industry. To meet the needs of this market we established a solid presence in the Krasnoyarsk Krai region with an office (+7.902.927.79.27) and a Russian language website: www.usnr.ru.
We are continuing to expand our business interests in this market by hiring Russian-speaking technical personnel to offer mechanical, controls, optimization and sales support for your systems. USNR has worked hard to win your business, no matter what region of the world you are located.
Whether expanding our network of representatives through associations with regional wood processing agents, or setting up our own remote facilities manned with USNR’s professional experts, we’re ready to serve your interests where you are!
EXPANDING SERVICE
EXPANDING SUPPORT
Technical service to meet your needs
Technical support that speaks your language
When you need us, our Russianspeaking technicians are available to service your equipment and systems. USNR offers service and suppor t for mechanical, electrical, optimization and controls systems. From installation and star t up to upgrades and repairs, we’re here to help!
We recognize that when you invest in capital equipment you need to be assured you can access suppor t when you need it. USNR is expanding its suppor t to the wood processing industry in this region with Russian-speaking technicians available 24 hours per day, 7 days per week. And our Russian-speaking contingent continues to grow!
RUSSIAN LANGUAGE OPTIMIZATION Optimization and PLC systems
MillExpert optimization is now available in the Russian language.
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An important element in the capability to offer advanced solutions to this region is optimization and PLC systems that are accessible to Russian customers and their personnel. USNR is proud to be able to assure Russian customers that our complete MillExpert™ optimization
platform is now available to them in their language. In the control systems realm, USNR’s WinTally™ sorter management system has been translated, and we are currently working on translation of additional PLC components.
The Boise Cascade mill at Elgin, Oregon is upgrading its gang optimization system with the latest MillExpert software release combined with USNR’s state-of-the-art BioLuma 2900L laser profile sensors.
Carrier Forest Products – Mill restart Carrier Forest Products Ltd. has contracted with USNR to retrofit its mill operation at Big River, Saskatchewan. The dimension lumber mill had been mothballed for several years and was subsequently acquired by Carrier. The retrofit will consist of optimization software and computer upgrades for the existing lineal gang and edger lines, as well as replacing the obsolete Hydra sensors with USNR’s LPL sensors. The edger’s RoboGuide™ system will also be upgraded. The sawmill trim/sort line will receive a new Multi-Track Fence and dual articulating smart (drop out) gate, optimization software and computer upgrades, and a WinTally™ system. The planer line will receive a Lineal High Grader (LHG) automated grading system, Multi-Track Fence, grade projection system and WinTally™ system. The mill’s large log line, edger, trim/sort and planer lines will all be upgraded with the ControlLogix PLC platform. Improvements in the lumber market heralded the decision to restart the mill. The project is targeted to maximize recovery and throughput, and improve system reliability to bring it up to today’s standards.
Chugoku Lumber – Edger BioVision The Chugoku Lumber mill at Kamisu City, Japan has ordered a BioVision™ edger grade scanning system from USNR. The USNR BioVision Grade Scanning System is the next step in optimizing for lumber grade in the sawmill. USNR has combined the proven Linear High Grader (LHG) technology developed for planer mills with new high resolution BioLuma 2900V color sensors for transverse scanning of lumber. The BioVision Grade Scanning System is designed as a plugin/bolton option for any MillExpert™ or Newnes Sawmill Suite™ transverse scanning optimizer system. With BioVision Scanning biological lumber defects are combined with existing precision geometric data to extract the highest value grade solution available in each piece of lumber.
Deltic Timber – Transverse High Grader (THG), planer line upgrades The Deltic Timber operation at Waldo, Arkansas is investing to update its planer mill with the latest technology from USNR. The 20’ line will receive a full-featured THG system as well as Revolver Lug Loader, MultiTrack Fence, Cut-N-Two recirculation transfer, WinTally™ sorter management system, TrueRead™ XL Grade Mark Reader, and associated trim line lumber transfers and operator console. The THG utilizes time-tested technology derived from the Lineal High Grader (LHG) image analysis and optimization software, combined with the best sensor available today. The BioLuma 2900LVG+ sensors collect ultra-high resolution images and precise geometric and grain angle measurements along the entire four surfaces of the boards. These improvements will assist the Waldo operation to achieve significant uplift to the value and grade distribution of its products, and improvements to throughput and recovery.
Douglas County Forest Products – TransLineator™ Planer Outfeed The Douglas County Forest Products operation at Roseburg, Oregon has invested in the revolutionary new TransLineator Board Feeding System for its planer mill. The new supply includes a TransLineator system located at the outfeed of the planer. This TransLineator outfeed will include a linebar fence and 3 sets of powered cone-shaped rolls that are dynamically balanced for high speed operation. The TransLineator will receive the 8’ to 10’ long planed boards and rapidly transfer the boards from lineal to transverse travel, while slowing them down before depositing them onto the landing table. This unique new TransLineator outfeed system will replace the mill’s existing double slow down belt configuration. It will significantly smooth the flow of lumber exiting the planer and pave the way for future upgrades, such as Virtual Lug Loader.
Tolko – 3 PGLRs and Log Line Optimizer The Tolko, High Level, Alberta mill is upgrading its 3 primary breakdown lines with Precision Geometric Log Rotation (PGLR) systems, one of which will be installed on the mill’s USNR Knuckle Turner Infeed. The existing outdated optimizer on the mill’s twin line will also be replace with a new MillExpert™ optimization system with LPL scanning. The PGLR system is a real-time rotation verification and correction system that ensures you get the best turn on every log, significantly improving cutting accuracy and increasing uplift and recovery.
ER D I S IN
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NEW PROJECTS
Boise Cascade – MillExpert BioLuma 2900L Gang Upgrade
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ISSUE 2 - 2013 | Millwide INSIDER 27
PO Box 310 Woodland, WA 98674
Millwide INSIDER is printed on recycled paper.
PROFILE
With over 100 years of combined experience in the industry, USNR’s international sales team provides solutions to our customers around the globe.
Pictured, left to right: Oksana Filina, Toby Slagle, Allan Czinger, Vern Pittman, John Reed and Lydia Volkova.
UPCOMING EVENTS
USNR offers the most complete line of sawmill and planer mill equipment on the market. With our line of Coe equipment for engineered
wood production, USNR is the largest supplier of integrated sawmill technology in the world, with an unmatched ability to deliver comprehensive solutions to international customers. A leading supplier with an impressive por tfolio of products, USNR has built sawmills and plywood plants in many countries all over the world. Toby Slagle, International Sales Manager said, “USNR is expanding its global reach, with a
multitude of success stories from international customers facing unique challenges and oppor tunities.” Many regions are ramping up for an upswing in demand for high quality wood products. USNR’s international sales team will be on hand at LIGNA to discuss ways we can help customers prosper with many new, innovative solutions.
MAY 6–10 Ligna
JULY 18–21 MLMA
SEPT. 20–21 KFIA
Hannover, Germany
Biloxi, Mississippi
Lexington, Kentucky
JUNE 5–7 SFPA EXPO
JULY 31–AUG 4 SLMA
Atlanta, Georgia
Point Clear, Alabama