THE MAGAZINE FROM USNR | ISSUE 2-2014
ROSEBURG INVESTS IN NEW TECHNOLOGY FOR ITS KILNS
MURRAY TIMBER GOES ASYMMETRICAL ON SIDEBOARDS
CAHABA VENEER HEATS UP WITH AN INSULATED DRYER FLOOR
CONTENTS
Millwide Insider ISSUE 2 - 2014
Strategic investing Many times, a company finds it is most practical to invest in brand new equipment. This will provide all the benefits of the latest technology combined with the most current processing concepts, and machines that will recoup a return over a long, long time. Other times it is more practical to simply take what you have − or what you can obtain as used − and invest in technology that will bring it up to today’s standards for per formance. Either choice can be a wise investment if it fits into your strategy for success.
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ROSEBURG Roseburg recently embarked on a major retrofit to its kilns to increase its capacity for producing kiln dried Douglas fir products. The retrofit entailed reroofing 8 of its kilns, upgrading its Kiln Boss controls and adding SCS in-kiln moisture measurement. Since project completion it has been exceeding its goals.
KILN TECHNOLOGY Now might be a good time to update your kilns. Our Kiln Boss PLC control is receiving many orders, and integrated with SCS wireless moisture measurements this combination can automatically advance your kiln operation. We also offer MyMill™ mobile control that will allow you to monitor and control your kiln process from anywhere on your plant site.
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SUBSCRIPTIONS Tel.: 250.833.3028 subscriptions@usnr.com EDITOR Colleen Schonheiter colleen.schonheiter@usnr.com CONTRIBUTING EDITOR Sonia Perrine sonia.perrine@usnr.com
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
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USNR LOCATIONS Woodland, WA Headquar ters 360.225.8267
MURRAY TIMBER Several years ago, Murray Timber installed a log line that blended pattern sawing with scan-and-set concepts. Recently it took this hybrid design to new lengths with an optimization programming change to allow it to produce asymmetrical sideboard solutions. The result is a big increase in value recovery of its sideboard products!
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CAHABA VENEER Cahaba Veneer was eager to increase its capacity when it acquired an older Coe M62 veneer dryer. It saw oppor tunity to improve energy efficiency and reduce maintenance with an insulated floor retrofit that was installed during the relocation of the dryer.
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POSTMASTER: Send address changes to 1981 Schurman Way, Woodland, WA 98674. Canada Post: Return Undeliverable Canadian Addresses to: USNR c/o Colleen Schonheiter, 3550 - 45th Street Southeast, Salmon Arm, BC V1E 1X1
New life for old kilns STRATEGIC INVESTING YIELDS IMPROVED QUALITY AND EFFICIENCY Roseburg's strategy for undertaking a major kiln retrofit project was to increase its capacity to produce kiln-dried stud products. It did that, and then some. Not only has the investment paid off with better-than-expected efficiency gains, improved lumber quality is a welcome bonus.
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ROSEBURG – NEW LIFE FOR OLD KILNS
An old kiln boasts a new roof.
A major refit to its dry kilns was what Roseburg was banking on to increase drying capacity and capitalize on a burgeoning market for kiln dried products. At the same time it implemented kiln technology improvements that are positively impacting its efficiency and the quality of its output.
Roseburg's Jeff Thompson
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Roseburg, located at Dillard, Oregon, is one of the largest capacity sawmills in the US. The company has a rich heritage that dates back to the 1930s and the time of the Great Depression. It was founded by Kenneth Ford and today remains a closely held, familyowned enterprise. The company started out as a sawmill, and later added plywood manufacturing to the mix. Today the Dillard complex comprises a sawmill, kilns, planer mill, plywood plant, particle board plant, and cogeneration power house. The company also has operations in Montana, California, Louisiana and Mississippi. It is among the greatest exporters of wood chips, and boasts one of the nation’s largest engineered wood products manufacturing facilities.
A section of roof is complete, while another old roof has been removed awaiting installation of the new construction. Jeff Thompson is general manager of the operation. He relates that the sawmill is primarily a stud mill, and also produces landscape timbers. Products are marketed domestically. Most of the logs processed are Douglas fir, with some hemlock and white fir also included. The sawmill operates on 3 shifts, processing roughly 400mbf annually. The mill was drying 70-75% of its production and selling the rest green, but it wanted to increase the dry output to improve margins and to respond to opportunities in the market.
The project comprised re-roofing 8 kilns, upgrading Kiln Boss to control those 8, and adding SCS moisture sensing. At the same time Roseburg undertook a steam conversion to increase capacity from 10 to 50 lb. extraction. The steam conversion served to increase the heat applied to the process, and decrease the drying time.
Our biggest challenge was downtime, and USNR really helped us with that by staging the delivery.
Below: Finished roof sections
Scoping the project For this project, Roseburg chose 8 of its kilns to be re-roofed; 6 double track kilns and 2 single tracks. Four of the kilns were part of the original millsite (early 1940s vintage) and the other 4 were added in the 1960s. Jeff commented, “The decision to upgrade the kilns was really driven by the market. With where we thought it was headed, we decided to invest to capture more of the dry stud market. That sector is expanding, and we get a premium on dry stud products.�
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ROSEBURG – NEW LIFE FOR OLD KILNS
A worker checks one of the fans inside a kiln after re-roofing is complete.
Phasing delivery The re-roof project was done in phases, with 2 roofs delivered at a time to allow continuous production and not overwhelm the lumber storage area. Jeff commented, “Our biggest challenge was downtime, and USNR really helped us with that by staging the delivery. We took 2 kilns down (functionally), tore the roofs apart and reroofed while we were able to keep the other 6 functional.” He went on, “Safety was of utmost concern, but we were able to do the whole project without losing any production in the sawmill or planer.” From USNR’s perspective the biggest challenge was determining how the old
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roof was constructed and supported as no drawings of the old roof could be found. As well, coordination and timing of roof delivery and installation was critical to maintaining Roseburg’s production targets. Overall the project took about 4 months to complete.
Precise control with Kiln Boss and SCS Moisture Sensing All 8 kilns are operated via Kiln Boss controls integrated with the SCS in-kiln moisture sensing system, to advance the drying schedule automatically from fiber saturation point (typically 25% to 27% moisture content) down to the equalization or conditioning step. Then it is designed to shut off the kiln once the average
KILN #1
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KILN #2
The kilns run a complete cycle without interruption; no wasted time and no wasted energy.
moisture content target is reached; the system is proven to within 1% moisture content accuracy. These 8 kilns were already using the Kiln Boss system, and with the project it was upgraded to the latest version release.
KILN #3
KILN #4
The SCS in-kiln moisture sensing system was new to Roseburg. (See page 8 for detailed information about Kiln Boss and SCS moisture control.)
Improved process Jeff compared the old process with the new one. “In the past when the kiln cycle reached a stage where the operators thought it was done, they would shut the kiln down and open the doors allowing it to partially cool, and then test the wood with a hand meter. If it wasn’t quite done they had to shut the doors, heat the kiln back up and dry for additional time. Each time we lost a huge amount of energy. Now with the in-kiln moisture meters, the sensors tell us when the load is done. The kilns run a complete cycle without interruption; no wasted time and no wasted energy. They automatically shut down when the target moisture content is achieved.” He continued, commenting on training of new kiln personnel. “We now have 3 different brands of control systems on our kilns, and USNR’s is by far the most userfriendly and easiest to learn. That is where we first focus training our new people because it is very intuitive, and the in-kiln moisture meters take out the guesswork.”
an overall increase in the quality of the lumber.” He is also pleased he decided to go this route instead of replacing the kilns. He said he did consider other vendors, but was most familiar with USNR and Coe drying systems. “We knew USNR was a pretty safe bet.”
We were hoping to increase our percentage of dry output to 85%, and we are currently exceeding that. We are seeing an overall increase in the quality of the lumber.
Jeff gives credit to Marshall Ledbetter, dry kiln supervisor, and Lee Weaver, lead pipefitter, for making the project a success. USNR’s Steve Edmonds handled the Kiln Boss controls upgrade, working with Scott Schneider for the SCS in-kiln moisture sensing system. This project is proof positive that sometimes the smartest investment can be to retool older systems with new technology to bring them up to today's standards. Not only can it reduce downtime and greatly extend the life of valuable assets, it can allow mills to remain competitive for the longer term. Every situation comes with its own challenges, and USNR is pleased to work with our customers to achieve a successful outcome every time.
Responding to the market Jeff is well satisfied with the results of this project. “We were hoping to increase our percentage of dry output from 70% up to 85%, and we are currently exceeding that. With the in-kiln moisture sensing system integrated with Kiln Boss we are seeing
KILN #5
KILN #6
KILN #7
KILN #8
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Kiln Technology
Turn up the heat GAIN PRODUCTIVITY, EFFICIENCY AND BETTER QUALITY LUMBER Designed to minimize operating costs without sacrificing product quality, the latest in drying technology advancements are combined with configuration flexibility to provide a dry kiln system uniquely suited to your specific lumber drying needs. More and more customers are taking advantage of the uptick in the market to invest in their drying systems. USNR has taken a large number of orders recently for Kiln Boss and SCS in-kiln moisture systems upgrades and retrofits. Many of these orders are resulting from outdated controllers that are being converted to industry standard hardware and software platforms for greater
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control of the process and improved supportability. USNR offers Kiln Boss, SCS in-kiln moisture sensing and MyMill™ mobile kiln control systems that offer the latest hardware and software available to take your drying process well into the future. Our systems can be implemented with new kiln installations, or as a retrofit to existing dry kiln systems.
Millwide Insider | ISSUE 2 - 2014 | www.usnr.com
Is it time to upgrade your kiln technology? Read on to learn about some of the unique technology solutions that will improve your lumber drying operations. Contact us at 800.BUY.USNR, +360.225.8267 or info@usnr.com for an evaluation of how the latest technology can achieve better efficiency, productivity and product quality from your system.
USNR’s Kiln Boss automates the drying process from start-up to shut-down. It provides greater control of heat, moisture, fan and air velocity − all integral components of efficient kiln operation. Currently, the Kiln Boss control system is operating in over 180 kiln systems worldwide.
Kiln Technology
KILN BOSS PLC CONTROL SHOWS OFF ITS INTERFACE FEATURES Opposite page: The Kln Boss graphical overview screen provides a view of the temperature values for each zone and section of the kiln. It displays information about the setpoints, fan reversals, step time, run time, as well as the status of the heat valves, vents, spray, and fans. From this screen the operator can manually control the fans, heat valves, and spray.
USNR recently redesigned the user interface to make it even more user friendly. “We modified the interface so that it would have the same look and feel as other USNR control systems throughout the mill. This helps in training personnel to operate the kiln,” said Steve Edmonds, USNR’s engineering manager in charge of dry kiln controls. “One major advantage to the new interface is that it will make it easier for mill personnel to go from one USNR system to another, and quickly be able to navigate the various screens.”
It will make it easier for mill personnel to go from one USNR system to another, and quickly be able to navigate the various screens.
The kiln schedule screen above allows the operator to assign set points (dry bulb, wet bulb, fan reversals, fan speeds, moisture contents, etc.) that are used to dry a charge of lumber. The operator can save up to 40 schedules (for different species, thicknesses, etc.) all ready to load with a mouse click.
He also noted the development of additional displays to provide even greater control of kiln operation, and anticipating tightening of EPA and safety standards. “Fuel handling systems have become much more involved, with greater reporting and safety interlocks, especially when using a green fuel burner on a continuous kiln.” He went on to explain that screen and program enhancements vary based on the type of kiln being controlled, be it a continuous kiln or a batch kiln, and using steam heat or a direct-fired process. Kiln Boss allows operators to examine and change the parameters for each of multiple kilns under the Kiln Boss system. It can be applied as a retrofit to any vendor’s existing kiln systems, or with new kiln installations.
The kiln chart above shows trending for specific variables throughout a kiln cycle. Variables include entering and exiting air temperatures, wet bulb temperature levels, and average moisture content.
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Kiln Technology
KILN TECHNOLOGY – TURN UP THE HEAT
SCS WIRELESS IN-KILN MOISTURE CONTROL You need never again shut down your kiln before the load has reached its target moisture content! USNR has joined forces with SCS Forest Products Inc. to bring you the industry’s best technology combination available to control your kiln operation.
Benefits
Improved moisture control has emerged as a critical process improvement element as mills focus on profitability and yield. SCS wireless in-kiln moisture control is fully integrated with Kiln Boss to ensure the target moisture content is reached, for the highest efficiency and best quality lumber with every kiln load.
Payback
Fully automatic control of the lumber drying process from fiber saturation until final moisture content target Confidently eliminate costly hot checks Integration with Kiln Boss makes training quick and easy Off-the-shelf hardware; order parts directly from any local distributor Installation and commissioning is limited to 1/2 day downtime, with clean and simple conduit runs
Most mills realize full payback in a period of 4 to 6 months. Productivity saving: 5-15% Moisture grade improvement: 1-3% Average drying time reduction: 11%
You can achieve these benefits of a fully integrated Kiln Boss control and SCS In-Kiln Moisture Control system through a retrofit to your existing kiln control system, or with new kiln installations.
How it works The SCS in-kiln moisture sensors measure the moisture content of the lumber as it dries, and wirelessly reports it to the Kiln Boss PLC controller. The moisture sensors use capacitance measurements to calculate moisture content. Each measuring point uses two stainless steel plates inserted between tiers of the lumber package, and stainless steel cables connect to the plates from the junction box. All electronics are located in the control room for greater system reliability. With the SCS moisture control integrated with the Kiln Boss PLC controller, the system automatically advances the drying schedule from the fiber saturation point until the final moisture content target is reached, and then shuts off the kiln.
The Kiln Boss moisture control screen displays SCS moisture sensor measurement data from the various moisture sensor locations in the kiln.
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Kiln Technology
MYMILL KILN MOBILE CONTROL Building on the success we’ve achieved with the MyMill™ system for mobile lumber sorter control, USNR has expanded the system to include dry kiln applications. All of the functionality that is available with USNR’s Kiln Boss control system can now be accessed via iPads/iPods from anywhere on the mill site within range of your inplant wireless network. MyMill works seamlessly through direct communication with your PLC control system. Response is immediate and accurate. The following mobile functionality is available with MyMill Kiln: Mobile control for all of your kilns Monitor the status of drying charges within each kiln Select or change drying schedules Monitor / set moisture probe temperatures Monitor / prioritize steam pressures Start / stop / reverse fans Actuate valves, vents and sprays
Easier troubleshooting and maintenance Reduces downtime
MyMill Kiln is available as an upgrade to USNR kiln controls systems, or with new kiln installations.
Built-in safety features Dedicated wireless infrastructure, on a secure in-plant network
Pause or shut down kiln / burner operation Monitor / acknowledge alarm Monitor / create maintenance schedules Actuate load transfers in continuous kilns Annotate messages to other team members
MyMill Benefits
MyMill Kiln allows monitoring, schedule changes and more, to be done from anywhere within range of the mill’s in-plant network.
Replicates all the functionality of a stationary HMI screen in a mobile device Real time data in the palm of your hand Mobile machine monitoring and control Powerful information and communications capability, functionality Replaces consoles, reduces capital cost
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Finely tuned for efficient drying performance.
Our customers expect efficient drying performance. USNR Package Kilns deliver. Faster,
more uniform drying Flexible drying schedules Complete drying control Energy efficient results that make a difference A history of proven performance
Reduced Accurate
energy consumption multi-zone temperature
control Lumber
dries lighter and brighter largest support staff 24/7 service Industry’s
Millwide. Worldwide.
800.BUY.USNR
info@usnr.com
www.usnr.com
Recovery breakthrough ASYMMETRICAL SOLUTIONS DESIGNED FOR PATTERN PROCESSING After several years of production and further improvements to its primary breakdown line, Murray Timber again approached USNR with an idea that would lead to a big increase in the value of its sideboard recovery.
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MURRAY TIMBER – RECOVERY BREAKTHROUGH Murray Timber has been well satisfied with the performance of its USNR primary breakdown line since its implementation several years ago. On the heels of a subsequent project to accelerate piece rate, the line recently underwent optimization and plc controls upgrades that are having an impressive impact on sideboard recovery. In 2006-2007 a USNR primary breakdown line was installed at Murray Timber Group’s (MTG) Ballygar, Ireland operation. Production Director John Murray has been well satisfied with the equipment’s performance to-date, but that has not stopped him from exploring ways to gain even greater throughput and value recovery. John contacted USNR a few years after commissioning to accelerate the line, increasing the mill’s return through economies of scale. At that time John remarked that he was, “100% satisfied with both the equipment and level of support provided by USNR.” More recently MTG decided to implement a further hybrid optimization component to this line with asymmetrical sideboard solutions, replacing the symmetrical solutions typical with a pattern log breakdown process. The USNR line is equipped with 3D Smart TriCam scanning and MillExpert Integrated Processing Line (IPL) optimizer. At time of installation it was USNR’s first pattern-
Log Ladder
Solution screen at right: The upper left quadrant shows the rotation solution from the Log Turner Scanner (below). The upper right quadrant shows the optimizer's solution from the first scan after rotation (station #1). The solution calls for sideboards to be recovered on all 4 sides, comprising a 16mm thick and a 22mm thick board at both top and bottom, and a 22mm thick board on each of the left and right sides. The bottom left quadrant shows the optimizer's new solution once the log has been processed by side chippers (station #2). In this solution the optimizer has sacrificed a 16mm board on the right side to recover an additional 22mm board on the opposing side. The bottom right quadrant shows the optimizer's new solution once the piece has been chipped again to form a 4-sided cant and scanned a fourth time (station #3). With asymmetrical programming, the optimizer calls for the machine to adjust the position of the piece via the vertical feedroll module ahead of the profilers, and recover two 22mm boards on the right side rather than the left. This asymmetrical solution increases the value of the sideboards recovered from this log.
specific optimizer; the IPL (Integrated Processing Line) is a hybrid design, allowing the mill to combine the high throughput of pattern processing with the increased recovery of sets optimized for each individual log’s 3D shape. It allows the basic sawing pattern to stay the same throughout a batch of logs. As originally designed, it would maintain a consistent center cant, allowing variations in the widths and thicknesses of 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. In this application no edger is required.
Redefined breakdown solution John wanted to take it a step further and redefine the breakdown optimization to provide asymmetrical sideboard solutions. This would allow the mill to produce the specific products desired to better match the mill’s discriminating markets. It would increase the value of the output by increasing the high demand products,
Quad Roll Log Turner
Log Turner Scanner
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THE ASYMMETRICAL
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Verification Scanner (station #1)
Chipper
Cant Turner
Scanner (station #2)
Chipper
Cant Turner
Scanner (station #3)
PROCESS EXPLAINED
Profilers
Separator Table
Quad Arbor Vertical Feedroll Modules (VFMs) Sawbox (QASB)
Cant Turner
Profiler
Versa Gang
Separator Table
Splitter Saw
VFMs
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MURRAY TIMBER – RECOVERY BREAKTHROUGH
With asymmetrical processing we can chase the high-demand board, while on the other side having a differentsized product that can also be in demand. It increases the value of the output vs. the input.
and eliminating the lower value products. “We wanted to be more clinical about what sideboard products we were producing. With symmetrical solutions we might end up with one high value board, and on the other side one that is far less desirable, or the possibility of not being able to achieve either. With asymmetrical processing we can chase the high-demand board, while on the other side have a different-sized product that can also be in demand. It increases the value of the output vs. the input.” The raw material processed at Ballygar is plantation Sitka spruce. The top end log diameters range from 4 to 14 inches, and are precut in the forest to lengths of 8, 10, 12, 14 and 16 feet. All logs are presorted to within 1 cm, so the mill can run continuous batches of homogenous material with very short gaps between pieces. This breakdown machine is 105 meters long, comprising four scanners, three cant ring-turners, two canters, three profilers, two board separators, a sawbox to remove up to four sideboards, a versa gang and a splitter saw. The optimization refinement for this project affected 3 of the 4 scanners and plc controls for the downstream end of the machine center.
the next turn.” Andre further explained that if there is not enough fiber to make a side board on both sides of the block, the previous solution would not make a board on either side. With this new concept the block is shifted ahead of the profilers, and then can cut off a single side board, if desired, or varying sideboard products on either side.
Impressive gains John went on to explain that with the redefined optimization the cutting tools all stay stationary, while the vertical feed module (VFM) positions the piece relative to where the sideboards will be taken off. The centerline does not change, but the piece will move to pick a sideboard product if it is available. “We are achieving a better recovery than we expected. We expected a certain amount of recovery uplift, and we’ve achieved double that amount.”
Hybrid benefits This hybrid breakdown concept provides the benefits of scan and set processing while retaining the benefits of running pattern production. John is happy with the results of the upgrade, “It is doing exactly what we thought it would do.” John went on to explain that the project process involved both USNR and MTG teams working to make it a success. “There was a period where we took step backwards to go forwards. We had to take ownership of the system to allow us to achieve what we wanted to. The work that was done by USNR gave us the canvas, and we progressed the improvements from that.” To bring this project to fruition involved both optimization and PLC controls rework. The major players on the MTG team in this project were Martin Conroy who is in charge of production, and Michael Naughton who
How it works Andre LaPierre, USNR controls engineer, explained the process. “Each piece needs to be on center when going through each of the 3 ring turners, but does not need to remain on center for processing. We shift the piece via the vertical feed modules to hold the block off center as we make the cuts, then move it back on center for
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We are achieving a better recovery than we expected − we've achieved double that amount.
handles PLC controls. From USNR were Dwayne Fujima on optimization, Andre LaPierre on PLC controls, and Jim Sosa as project manager who also performed the installation and testing. John Reed, USNR Senior International Account Manager, has a long history working with John Murray and the MTG group. “The Murray Timber team are very professional sawmillers. This whole line is 343’ (105 m) long with just one operator. And the line typically runs with 98% uptime.” Improving world markets combined with a doubling of recovery from its sideboards will pave the way for further progress in MTG’s continuing process evolution.
Cahaba Veneer
Veneer dryer renewal INSULATED FLOORS MAXIMIZE IMPACT OF IMPROVED CAPACITY When times are good in this business they can be very good, so when fortune smiled on Cahaba Veneer with the opportunity to increase veneer dryer capacity to keep pace with a bustling market, it was an easy decision to invest. Increasing capacity was the driving force behind Cahaba Veneer's decision to purchase a used veneer dryer. It would allow this hardwood veneer plant to meet its production goals and respond to a brisk
market. During the process, an insulated steel floor was installed to reduce maintenance and improve energy efficiency.
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CAHABA VENEER – VENEER DRYER RENEWAL Pete Browder is the owner of Cahaba Veneer of Centreville, AL, and has seen his share of ups and downs in the industry. From the time he was very young he worked in his father’s veneer mill, Sumter Veneer (now closed). Pete turned his sights to owning his own plant, and he took over Cahaba Veneer in 1997. Cahaba Veneer is located on one of the oldest mill sites in Alabama. Started in 1906, it was originally named W.E. Belcher Lumber Company and was a major sawmill operation. In time a veneer plant was added to the site, and today that is the operation owned by Pete Browder, while a neighbor operates the sawmill.
Designing a plan With two veneer dryers already on site, Pete wanted to increase the drying capacity. The existing dryers were a Coe M72 gas fired system that was installed in 2004 and a Coe M62 steam-heated system that was installed in 1962 (the very first Coe vert-ajet dryer ever manufactured). When another (circa 1998) Coe M62 3-deck gas-fired dryer became available at a site 20 miles away, Pete jumped at the chance to acquire it. Though it had been idled for several years Pete knew it could solve his dryer capacity bottleneck. During the process of relocating the dryer to Centreville, Pete decided to investigate installing an insulated steel floor rather than using a concrete foundation that is typical for these dryers. The economics made a lot of sense, as the insulated floor would be more economical to install and require far less maintenance long-term. He expected it would also improve energy efficiency.
M62 dryer was a Coe design it made sense to install new USNR parts that were made to OEM design specifications.” The plant processes primarily hardwood logs of various species. “We process logs into cut-to-size specialty hardwood veneers. In this market, if a customer has a specific specialty they will request any variation of size within the mill’s capabilities.” Much of the plant’s output goes to secondary manufacturers to be made into engineered flooring, but there are many other hardwood veneer applications such as ceiling tiles, woven and acoustical baffles, and furniture.
Project scope The project required USNR to install new steel support piers for reinstalling the dryer on a flat factory floor, while maintaining the elevation of the machine from its
It made sense to install new USNR parts that were made to OEM design specifications.
previous installation. The project scope also included all new fasteners and sealing materials for reassembling the dryer. The insulated floor consisted of 5 steel panels for each of the 4 heated sections and one cooling section. The floor was welded into the dryer to form a completely sealed unit. Additional structural steel was included to support the panels and longitudinal stiffening between the dryer’s existing bottom cross beams.
The insulated floor consisted of 5 steel panels for each of the 4 heated sections and one cooling section. Below shows the cooling section insulated floor was yet to be installed.
The advantage of OEM designs Though Pete did look at other vendors for the insulated floor, he chose USNR for several reasons. “I have a long-standing relationship with Coe, and I don’t know USNR. Since USNR acquired the Coe assets I was very happy because I have a lot of Coe equipment and was assured to receive ongoing support. I also wanted to develop a relationship with USNR, and to support the company’s venture into the Coe equipment line.” He went on to explain, “Because the
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COOLING SECTION
The one challenge this project presented was planning for the attachment of the cooling section directly to the dryer during reinstallation, a first for this type of dryer. This aspect required field modifications and fabrication that was performed by the Cahaba Veneer/USNR installation team.
feet per hour, running 24 hours/day and 5 days/week. The M72 dryer is a 4-deck while the older M62s each have 3 decks.
insulated floor is more energy efficient because it doesn’t have to heat up the concrete.” Pete also mentioned how pleased he was with the support he received from USNR during the installation process.
Though he hasn’t measured energy consumption for each, Pete remarked, “We believe we'll find that the dryer with the
Besides the three Coe dryers, Cahaba Veneer operates two Coe M263 veneer lathes. Pete Browder noted that the plant is presently enjoying a very brisk market, a dramatic change from what it saw over the past few years. With improved drying capacity, the operation is well equipped to meet its production goals.
Increased capacity The re-commissioned dryer was started up in December 2013, and Pete is happy with the results of the project. “We are getting very good veneer quality, consistently dry veneers, and it is doing exactly what I anticipated it would do.” The capacity of the relocated dryer is approximately 1000 board feet per hour; the overall capacity of all three dryers is in the range of 2500 board
We believe we'll find that the dryer with the insulated floor is more energy efficient because it doesn't have to heat up the concrete.
RETROFIT YOUR DRYER WITH AN INSULATED FLOOR USNR’s insulated floor is designed to retrofit existing dryers of all configurations. New floor panels fabricated from mild or stainless steel are installed over the existing concrete floor that is typically found in most older dryers. The seal weld installation completely eliminates leakage around the foundation, keeping more thermal energy inside the dryer to improve dryer productivity. The insulated floor upgrade significantly enhances dryer performance and gives new life to your existing dryer. Improved dryer alignment and expansion reduces plug ups
and lost operating time. Foundation sealing that is normally required around door frames is eliminated. Advantages of a stainless steel insulated floor include: Reduces energy consumption Improves dryer productivity Prevents further foundation deterioration Eliminates leakage Easier cleanout
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Panel Sales Team
Left to right; Dusty Burchfield, Tim Fisher, Trevor Wendt, Arne Nordstrand, Alan Knokey, Pete Volk, Tim Davis, Bryan Wolowiecki
Growing the team WE’RE EXPANDING OUR NETWORK TO SERVE YOU BETTER Our panel business is growing, and so are we! We’re investing in the future by bringing on board three veterans of this industry who are ready to hit the ground running to respond to your calls.
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Millwide Insider | ISSUE 2 - 2014 | www.usnr.com
Alan Knokey, Vice President and manager of USNR’s Panel Division, said “Each one of these people brings a wealth of dryer experience and business knowledge to our group. Adding their exper tise to our team will help USNR continue delivering great products and service to our customers. We’re excited to have them on board”.
Pete Volk
Tim Davis is our Technical Sales Representative, and as such he will focus on Jet Dryer upgrades and repairs. Tim has 30 years of experience in the drying industry which includes veneer, gypsum and mineral board products. He was most recently the CEO and owner of Advanced Mill Solutions located at Eugene, Oregon. Prior to starting AMS, Tim worked for Grenzebach, BMH and AKI (manufacturers of drying systems). He is based at USNR’s Eugene, OR facility.
Pete Volk, Account Manager Press Systems came to USNR in 2009 and has over 42 years in the Press Systems industry. Prior to joining USNR, Pete worked for Lamb Grays Harbor, Washington Iron Works, Coe Manufacturing and American Iron Works.
Bryan Wolowiecki Bryan Wolowiecki, Account Manager signed on with USNR in 2009 and has over 21 years in the panel equipment industry. Prior to joining USNR Bryan worked for Coe Manufacturing.
Dusty Burchfield Dusty Burchfield joins our mechanical design team, and he will focus on Jet Dryer upgrades and repairs. Dusty has 18 years of experience in the drying industry including veneer, gypsum and mineral board products. He was most recently employed at Advanced Mill Solutions as Chief Engineer/ Project Manager. Prior to joining AMS, he worked for Alco Contractors, Grenzebach, BMH and AKI. Dusty will be supporting both dryer engineering and sales, and will be based out of USNR’s Eugene, OR facility.
Alan Knokey The team New to USNR, Trevor Wendt, Tim Davis, and Dusty Burchfield join our well-known panel equipment sales experts comprising Alan Knokey, Tim Fisher, Pete Volk, Bryan Wolowiecki and Arne Nordstrand.
Trevor Wendt Trevor Wendt joins us as a Major Account Manager serving both regional and international accounts. Trevor is based in Vancouver, BC and will represent the full breadth of USNR’s panel manufacturing machinery product line. He has 18 years of experience in the wood products industry working with CIPA Lumber, Raute, Carmanah Forestry Systems, and most recently at Westmill as Sales and Marketing Manager. He holds a degree in Business Administration from Simon Frasier University.
USNR’s newly expanded panel team is ready to meet your challenges head on with many decades of experience in this field. We know that uninterrupted performance and high quality panel production is critical. Get the most out of your system with unique and reliable upgrades designed by the people who understand panel processing machinery better than anyone in the business. To reach any of our panel equipment team members, please contact us at 800.BUY.USNR, +360.225.8267 or info@usnr.com.
Alan Knokey, Vice President joined USNR in 2009. Prior to joining USNR, Alan was Executive Vice President of Coe Manufacturing, where he worked for 42 of his 47 years in the panel equipment industry.
Tim Fisher Tim Fisher, Senior Account Manager came to USNR in 2010 and has over 39 years in the panel equipment industry. Prior to joining USNR, Tim worked for Grenzebach, Coe Manufacturing and Georgia Pacific Machinery Division.
Arne Nordstrand Arne Nordstrand, Account Manager rejoined USNR in 2013 and has over 39 years in the sawmill and panel equipment industry. Prior to joining USNR, Arne worked for Nordstrand Cedar Products, USNR and Raute.
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Panel Sales Team
Tim Davis
NEW PROJECTS AKD Softwoods – MyMill mobile control
Coastland – Veneer dryer retrofit
Hyne Timber – BioVision edgers
USNR’s MyMill™ mobile control technology will be implemented at AKD Softwood, Colac, Australia. The mill has ordered the MyMill system for its sawmill sorter, and joins 16 other mills that have ordered this new technology. To date, MyMill systems have been sold or installed in USA, Canada, Russia, New Zealand and Australia.
Coastland Wood Industries of Delta, BC is investing in major improvements to its veneer dryer that will turn it into a powerhouse for drying performance and efficiency.
The Hyne Timber operation at Tumbarumba, NSW, Australia is updating its two sawmill edgers with advanced technology from USNR. The mill processes Radiata Pine into dimension lumber products, with maximum lengths of 6.0m.
Canfor – NSS Trimmer upgrade Canfor, Isle Pierre Division at Prince George, BC is upgrading its Newnes Sawmill Suite trimmer optimization platform with the latest version release. The trimmer optimizer dates back to 1999 vintage. Among many improvements, the new software will also focus on end defect classification to reduce the chance for overtrim or improper reman solutions. It will also improve the system’s supportability going forward.
Sawmill BioVision scan frame for edgers and trimmers.
The newly acquired and relocated 20 section M72/95 Coe veneer dryer will be retrofitted to add a complete Automatic Exhaust Control System (ADEC) with wet end seal section and a single-point discharge at the infeed end. The ADEC system is designed to automatically control total dryer exhaust volume, maximize thermal efficiency and maintain the absolute highest internal dryer humidity condition to produce very high quality veneer. Coastland has also ordered a Cooler Pressure Balance Control system. This system controls the pressure balance between the drying sections and the cooling sections. This greatly reduces any flow of heated process air between the drying and cooling sections, improving the dryer’s thermal efficiency even further. This also reduces pitch buildup in the dryer and reduces VOCs in the exhaust stacks. Along with these energy efficiencies, Coastland will install a complete new AB ControlLogix dryer PLC system. The new PLC will control the main fans, drive, zone temperature control, ADEC, Cooler Pressure Balance, dryer drive rig, and sequencing of dryer feeding and unloading equipment.
Collums Lumber – Planer mill modifications The Collums Lumber mill at Allendale, South Carolina is investing in modifications to its planer mill. Included are retrofits to its existing Continuous Tilt Hoist, two new Quad Cam Board Feeders, 20 additional sort bins with related sorter top, and package area improvements.
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Millwide Insider | ISSUE 2 - 2014 | www.usnr.com
The mill is investing in a BioVision™ system for its two edger lines, allowing the mill to maximize its potential for grade and value recovery in its products. Edger BioVision provides value through remanufacture or rip based on the ultimate grade of the piece. For example, a #3 appearance due to knots can be edged to #3 wane, maximizing recovery. Likewise a low grade, wide piece may be worth more if ripped into two narrower boards, one of them being high grade. Edger BioVision grading at the sawmill allows for better decisions at an early stage in the process, before the boards are edged or trimmed. This BioVision edger system is designed with the following major features: Dimension lumber grade optimization M oulding and industrial shop optimization K not location, classification, measurement D ecayed/unsound knot classification B ark encasement/bark encased knots S plits and shake G eometric characteristics, wane and tearout
The order includes two new scan frames, each outfitted with 22 BioLuma™ 2900LV sensors. HD laser profiling along with HD color resolution offer the necessary building blocks to ensure even minute defects are detected for highly accurate grade classification.
COMPLIMENTARY SUBSCRIPTION For your complimentary subscription to USNR’s Millwide Insider magazine e-mail subscriptions@usnr.com or go to www.usnr.com/about/news
Hyne Timber – LHG & WinTally upgrades
J.H. Huscroft – MillExper t Trimmer optimizer upgrade
Hyne Timber is also updating its Lineal High Grader (LHG®) automated grading line with the latest software release, offering enhanced machine grading capability. At the same time, the WinTally™ sorter management system will be updated with Ver. 7.0 software.
The J.H. Huscroft mill at Creston, BC is updating its sawmill trimmer to the MillExpert optimization platform. The mill’s existing M6 scan frame and sensors will be reused, while the optimization platform will be updated to the latest MillExpert version release.
With the LHG and WinTally systems working in tandem, the mill can access advanced sorting capabilities. With integrated product setup, the system can turn on/off products at the LHG based on sort orders, product mixing limits and jag pack management (minimizing the number of unfinished packages at the end of a run).
J.D. Irving – NSS Edger upgrade J.D. Irving mill at Valley, Nova Scotia is updating its edger optimization to the latest Newnes Sawmill Suite version release. The edger optimizer dates back to 1999 vintage. Among many other improvements, the software will support the new ripping module that affords the capability to make a rip solution to process at the edger rather than another downstream location. It will also improve the system’s supportability going forward.
As part of the order for the new dryer, the plant has ordered the Automatic Dryer Exhaust Control (ADEC) system and Cooler Pressure Balance control to obtain maximum operational efficiency, and maximize veneer quality.
Scierie VOG – MillExper t LASAR carriage optimization The Scierie VOG operation located at Plessisville, Quebec is implementing USNR’s MillExpert carriage optimization system with front and back side LASAR scanning.
Nor thwest Hardwoods – Kiln Boss and SCS controls The Northwest Hardwoods operation at Eugene, Oregon has ordered Kiln Boss controls and SCS in-kiln moisture metering for 11 of its existing kilns. With integrated Kiln Boss and SCS systems, kiln operation is fully automatic from the fiber saturation point down to your final moisture content target.
Produits Forestiers D.G. – MillExper t/LASAR carriage opt.
This MillExpert / LASAR combination has been very successful in both softwood and hardwood applications. MillExpert’s intensive 3D graphics, SQL database and system modularity are hallmarks of USNR’s optimization products. LASAR sensors are well known in the industry, with the recently released third generation design for unequalled quality, durability and accuracy.
The Produits Forestiers D.G. operation located at Saint Come Liniere, Quebec has ordered USNR’s MillExpert carriage optimization system with LASAR scanning for its headrig carriage line.
Richmond Plywood – 6-deck veneer dryer with ADEC Richmond Plywood at Richmond, BC has ordered a new 6-deck, 14-section Model 208 veneer dryer. The dryer will utilize steam energy and comes complete with insulated floor and stainless steel cladding.
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PO Box 310 Woodland, WA 98674
Millwide Insider is printed on recycled paper.
Profile Bob Sunamoto is a Senior Account Manager for USNR. He is based at Woodland, WA. Bob Sunamoto is an industry veteran with nearly 45 years of experience. He received a Bachelor of Science degree from Oregon State University before joining Moore Dry Kiln Company in 1970, and Coe Manufacturing in 1982. Bob has been with USNR since 2009. Bob’s experience is primarily with lumber drying and handling systems. He recounts,
UPCOMING EVENTS
“One highlight of my career was working with a great team to install the first computerized multi-heat-zone dry kiln at Weyerhaeuser’s Raymond, WA mill. That project was completed in 99 days, and Coe Manufacturing was awarded Vendor of the Year in 1992.” More recently he was involved in the 165 ft. pole kiln project for Pacific Wood Preserving at Sheridan, OR in 2012, and the Roseburg kiln retrofit project at Dillard, OR detailed in this issue (see page 3). Bob’s hobbies include fishing, sports, travel and spending time with his wife, Lynette, his two children and three grandchildren.
JULY 10–13 MLMA
AUG. 20–23 IWF
SEPT. 26–27 InterSaw
Biloxi, MS
Atlanta, GA
Montreal, QC
OCT. 15–17 TP&EE Portland, OR