Insider
THE MAGAZINE FROM USNR | ISSUE 38
SUPERSAVER: FLEXIBLE BREAKDOWN CONCEPT SUITS ANY SIZE OF MILL
USNR’S LATEST NEW VENTURE SUPPORTS GROWING CLT MARKET
LEGENDARY PRESS LINE STAGES A COME-BACK, RENEWS INVESTMENT
CONTENTS
Millwide Insider ISSUE 38
We’re growing In March 2015 we announced the joining of USNR and Söderhamn Eriksson. Now we’ve appointed a strong, energetic leader to head our European operations as we expand our presence around the globe. We also introduce a new product, the result of collaboration with one of our close customers. This launches USNR into a growing sector of the industry – CLT, cross laminated timber.
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NEW LEADER, EUROPEAN OPERATIONS
SUBSCRIPTIONS Tel.: 250.833.3028 subscriptions@usnr.com EDITOR Colleen Schonheiter colleen.schonheiter@usnr.com
USNR
We’re proud to introduce Johan Johansson,
Woodland, WA: +1.360.225.8267
an enthusiastic new leader for our European
Mon. - Fri. 5:00 am - 5:00 pm PT
operations. His exper tise will help us broaden the USNR / Söderhamn Eriksson mark world wide. Read about his accomplishments and plans as he takes on this new challenge.
24/7 Service: +1.360.225.8267 www.usnr.com SÖDERHAMN ERIKSSON Söderhamn, SE: +46.270.746.00 Mariannelund: +46.496.218.00 Mon. - Fri. 07:30 - 16:30 CET
SUPERSAVER Söderhamn Eriksson introduced the SuperSaver concept for flexible, productive log breakdown, and over time it has evolved as needs and
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markets progressed. In this issue we relate two
POSTMASTER: Send address changes to
recent installations where this design is receiving
1981 Schurman Way, Woodland, WA 98674.
rave reviews.
Canada Post: Return Undeliverable Canadian Addresses to: USNR c/o Colleen Schonheiter, 3550 - 45th Street Southeast,
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Salmon Arm, BC V1E 1X1
D.R. JOHNSON USNR recently took on a development project to design a new cross laminated timber (CLT) press for a customer in Oregon. This new press is an entirely different animal from USNR’s experience with panel and tire retread presses. Key design features make it a very good choice for those looking to get into this emerging US market.
WASHINGTON IRON WORKS This legendary press line has undergone a transformation with updated technology. A recent rebuild project proves just how reliably and productively these signature presses can per form in today’s marketplace.
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New man at the helm NEW MANAGING DIRECTOR FOR SÖDERHAMN ERIKSSON USNR / Söderhamn Eriksson recently announced the appointment of Johan Johansson as Managing Director of its European operations. Mr. Johansson is based at Söderhamn, Sweden, taking over from Henrik Lefvert, who served in this role on an interim basis since March, when USNR acquired Söderhamn Eriksson. Mr. Lefvert continues as Managing Director of Cellwood Machinery AB, which was formerly affiliated with Söderhamn Eriksson. Mr. Johansson brings an abundance of experience to Söderhamn Eriksson. Early in his career he worked for Söderhamn Eriksson as an Area Sales Manager, but most recently he has served as CEO of BRUKS Group, a global leader supplying bulk material handling and processing equipment to many industries, including the wood processing industry. George Van Hoomissen, President and CEO for USNR / Söderhamn Eriksson, commented, “Johan has displayed great skill in steering BRUKS through challenging market conditions and building it into the successful company that it is today. I am confident that under Johan’s leadership we will make great strides in expanding our presence in Europe and around the world as we continue to integrate USNR and Söderhamn Eriksson.” Mr. Johansson commented, “It was not an easy decision to leave BRUKS, but I am anticipating many new challenges and possibilities as part of the USNR / Söderhamn Eriksson team. I am excited to be part of such a successful force within our industry.” Mr. Johansson is a native of Sweden, and is fluent in both German and English. He lives with his wife and three children near Söderhamn.
Q&A MI – One main focus during
JJ – My overriding goal is to
your recent tenure with BRUKS, was business development. What experiences will you draw on to expand the SE business?
strengthen the brand in markets where our products and systems are competitive and suitable. There is definitely unutilized potential in some regions, and the broad, combined SE / USNR product range makes it even more interesting.
MI – What do you feel were
JJ – Isolated to a single
your greatest accomplishments during your tenure at BRUKS?
issue, for sure the great financial improvements. Those were based on structural and organizational changes, and were focused on the actual market conditions and the technology required to achieve this.
MI – What do you initially see
JJ – My immediate challenge
as your greatest challenge to overcome with this new role?
is to rapidly come to fully understand the business and what’s currently driving it. To do this I need to learn more about our people, products and organization.
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SuperSaver
Save space, maximize your investment FLEXIBLE, EFFICIENT PRODUCTION FOR ANY SIZE OF OPERATION Söderhamn Eriksson’s SuperSaver concept for breakdown of logs and cants, applies a merrygo-round layout that directs material from one process back through the same cutting tools to perform the next process. The equipment performs multiple-duty processing for increased flexibility, and takes advantage of available space and capital investment.
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THE CONCEPT: EXTEND RESOURCES INSIDE THE BUILDING The SuperSaver concept, developed by Söderhamn Eriksson, creates the capability to work more efficiently, improving flexibility and production within a limited space. With this configuration, a reducer bandsaw is situated in the center of the building. Logs and cants pass through the headrig as many times as necessary to achieve the desired cutting pattern. Curve sawing is also possible. Each log and cant is scanned to determine the highest yield. With this design, flexible efficient production can be achieved for any size of operation.
SuperSaver concentrates the machines, and uses the capacity in the system for flexible sawing of logs and cants. Because processing is all concentrated in one location, it is easily operated by one person. Pre-sorting of logs is not required but will speed production. To date, over 60 SuperSaver systems have been installed world wide. A wide range of breakdown configurations have been applied with this concept, besides those described here. Ask us about how this concept can be employed for your operation.
Here’s how it typically works:
1. The log is fed through the machine and reduced on two sides with chip heads. Smaller dimension cants are sawn with as many cuts as needed, before being fed directly to the edger.
2.
Above: An operator at the Ramasal mill at Constitution, Chile, operates the new sawmill featuring the SuperSaver breakdown configuration from Söderhamn Eriksson. The story follows on page 6.
Larger dimensions are routed back through the scan zone and cutting tools for further processing. Side chip heads once again reduce the cant before it is sawn into the desired dimensions. Alternatively, when producing un-edged boards, the cant can be fed “standing up”.
3.
The center block (pictured page 7) can be fed back through the bandsaws for a third time. The bandsaws now operate as resaws to process the pattern of cuts as established by the optimizer.
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SUPERSAVER – SAVE SPACE, MAXIMIZE YOUR INVESTMENT
CASE STUDY: RAMASAL SAWMILL, CHILE In 2012, Rumasal Sawmill, at Constitution, Chile selected the team of Söderhamn Eriksson paired with regional agent Solecia, to update its mill. The transformation yielded a much more efficient operation, with added flexibility built in to the design.
Mauricio Munoz has over 20 years of experience with Chilean lumber production. Today he is running a brand new saw mill at Rumasal, Constitution, Chile, delivered by Söderhamn Eriksson in 2012. “I used to run three very basic saw mills to produce lumber, and with those old fashion facilities there was no guarantee for the business to survive much longer, therefore
Söderhamn Eriksson is a well-known key player in the Chilean market, and their experience along with their flexible concept to design sawmills, was crucial for me.
SUPERSAVER BANDSAW CONFIGURATION A B C D
True shape scanning of log Auto log rotation Log alignment Reducing
Logs
E Distance for sweep sawing F Band sawing G Edging
A
B
C
D
G
E
F
Boards for Edging
Cants
Boards for Trimming
Cants 1st PASS
2nd PASS
3rd PASS
4th PASS
SMALL LOGS
MEDIUM LOGS
MEDIUM LOGS
BIG LOGS
BIG LOGS
EDGING
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it was a must to invest in a high tech operation,” he says.
their Chilean agent Solecia, was a strong point that made us choose them.”
“In order to survive this business you need to always be looking for ways to increase the efficiency of the operation or, in other words, you need to increase your output from the same amount of raw material. The market is constantly expecting more quality products for a lower price due to the high level of competitiveness, and if you don’t improve your operation the business becomes easily a headache in very short time.”
Satisfying results
Natural choice A saw line from Söderhamn Eriksson was a natural choice for Mauricio Munoz. “Söderhamn Eriksson is a well-known key player in the Chilean market, and their experience along with their flexible concept to design sawmills was crucial for me when selecting a contractor,” he says. “Everybody knows Söderhamn Eriksson in Chile, and they are represented here by a good agent that provides a lot of confidence, as they produce a big portion of the engineering locally in this project.” Mauricio Munoz also has previous experience with Söderhamn Eriksson as he used to run Cambio debarkers at the previous mills.
The Rumasal mill produces in the range of 130,000 m3 pine/year (55 mmbf)in a two-shift operation. The mill started its production in 2012, and Mauricio Munoz said he was impressed with the way Söderhamn Eriksson managed this entire turnkey project.
gotten follow up visits from Söderhamn technicians, which have been very helpful to us. Their technicians and personnel are very skilled and have shown a lot of knowledge of our market and our way to do business and run projects.” The Ramasal Sawmill is now well positioned to take advantage of market variations with this new versatile, efficient breakdown system.
“Being that far from Sweden, it has been quite efficient,” says Mauricio Munoz. “Their agent Solecia works well in getting everything done properly, and helping to resolve the problems that this type of project could bring about. We also have
Their technicians and personnel are very skilled and have shown a lot of knowledge of our market and our way to do business and run projects.
Maximize flexibility, productivity The chosen solution for the Rumasal saw mill is the SuperSaver concept featuring a merry-go-round design. The line is comprised of a bandsaw quad with reducer discs and merry-go-round conveyors, as well as an edger optimizer system. “Rumasal serves mainly the domestic market in Chile. Sometimes the orders from customers are small, and other times they may vary a lot in terms of lumber dimension and specifications,” says Mauricio Munoz. “It is important that the mill is highly flexible and productive, and the merry-go-round design from Söderhamn Eriksson fits perfectly to this concept. This solution can also be provided by other European manufacturers, however factors like experience and a turnkey solution, that was available from Söderhamn Eriksson and
Center blocks are routed back through the bandsaws, now performing as a resaw.
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SUPERSAVER – SAVE SPACE, MAXIMIZE YOUR INVESTMENT
CASE STUDY: RED OCTOBER, RUSSIA Söderhamn Eriksson also recently delivered and installed sawmill equipment for the Red October sawmill located at the foot of the Ural Mountains, in Permskiy Krai, Russia. ”The new equipment has increased our production,” says Dmitry Pashkovskiy at the sawmill. The equipment that Söderhamn Eriksson delivered and installed consists of log intake, debarking line, saw line, edging line, board sorting line and waste handling system. Dmitry Pashkovskiy is Red October’s Commerce Director, and he comments, ”Before we opted for Söderhamn Eriksson, we visited a number of sawmills in Europe and compared them in great detail. This led us to believe that Söderhamn Eriksson’s equipment was best suited for our production and our market position.”
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Modernization at Red October According to Dmitry Pashkovskiy, the modernization of the sawmill was a necessity, as the old equipment required a greater amount of energy and personnel to operate, and the mill was receiving little support from the manufacturers. “Our former suppliers were not competitive any longer and could hardly help us with spare parts, let alone with new solutions and products. We needed a supplier that not only could provide us with quality equipment but also with full technical support.”
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We visited a number of sawmills in Europe and compared them in great detail. Söderhamn Eriksson’s equipment was best suited for our production and our market position.
New machines yield increased production
Quality is the tradition
Mr Pashkovskiy was eager to point out the new saw line’s many advantages, including the SuperSaver configuration. Among other things, he likes the greater flexibility of its merry-go-round design, processing logs and cants of a variety of dimensions and shapes, all with the same machinery. Another advantage is that the technology involved guarantees high chip quality. ”We get more chips than sawdust now – with the old equipment it was the other way around. For the first time we can now sell highquality chips to pulp mills,” he says, adding,”The new equipment has increased our production right down the line.”
Mr Pashkovskiy also praises Söderhamn Eriksson because in his opinion it combines a long and ancient tradition of quality with the latest, state-of-the-art technology. “They are famous for their machinery that is both reliable and of high quality, and rightly so. They have even succeeded in implementing advanced technology such as automation and optimization right down to the smallest details. I’m truly impressed by their know-how.” For more information about how our SuperSaver concept might benefit your operation, please contact us.
We get more chips than sawdust now. For the first time we can sell high quality chips to pulp mills. The new equipment has increased our production right down the line.
SUPERSAVER LAYOUT AT RED OCTOBER
logs
FLOW cants
cants
FLOW
FLOW
FLOW
LOG TURNER
REDUCER HEADS
QUAD BANDMILL
boards
SCANNER
FLOW
FLOW
EDGER
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D.R. Johnson
A Different Animal
The new CLT press at D.R. Johnson uses a modular window frame design that can be expanded to accomodate the needs of the market.
CLT PROJECT SPURS NEW EQUIPMENT DESIGN FOR NEW MARKET USNR lives and breathes innovation, partnering with customers to achieve their vision. This sometimes takes the company into uncharted territory, as was the case with its new press design for manufacturing cross-laminated timbers. USNR is accustomed to designing and building presses for OSB, MDF, and plywood, but this new CLT press is an entirely different animal. Key features make it a good choice for market pioneers looking to get into the emerging US CLT market. With USNR’s engineering elegance, a customer vision becomes a successful reality. 10
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The Johnson family operates a lumbermill and a glu-lam plant in the Pacific Nor thwest region of the US, and wanted to expand their product line to include crosslaminated timbers. They tapped USNR for a solution. The result is a unique modular CLT press that is meeting their needs today, and can be expanded to meet future needs.
Laura Meeker (left), USNR Mechanical Engineer and Valerie Johnson, President of D.R. Johnson stand by a 5-ply CLT panel produced on the mills’ new press.
The Johnson family has been in the wood products business in Oregon for over 50 years. Valerie Johnson and her sister Jodie Westbrook are second-generation owners of the business and are involved in the day-today operations. The company owns and operates three plants. Umpqua Lumber is located at Roseburg. The company’s mainstay, D.R. Johnson, is located at Riddle, where the company was founded in 1951. Riddle Laminators was added on the same site at Riddle in 1967. The mills produce dimension lumber, structural joists, planks, laminated beams, utility poles (up to 135 feet), and their latest product is cross-laminated timbers, or CLTs. Riddle Laminators was built to manufacture glue-laminated beams. Going forward, both the glu-lam beams and the cross-laminated timber panels will be produced and sold under the name D.R. Johnson. While CLT has been produced and used in structural projects in Europe for about 20 years, D.R. Johnson has received the first U.S. certification to manufacture the panels under a new standard approved last year by the American National Standards Institute (ANSI) (PRG 320-2012).
The company’s products were tested and certified by the Engineered Wood Association (APA). “This is not merely a new engineered composite panel product,” Lech Muszynski, a professor in the OSU Department of Wood Science and Engineering, said in a news release. “It’s an entirely new building technology that is revolutionizing the use of timber in construction and dramatically cutting the overall time for construction projects.”
Response to the product has been very positive. This reaction from the market is showing there are projects ready to design with CLT.
The certification paves the way for D.R. Johnson to market its 3-lam, 5-lam, and 7-lam CLT panels to an emerging U.S. wood building market. CLTs are engineered wood panels typically consisting of three, five or seven layers of dimension lumber oriented at right angles to one another and then glued to form structural panels with exceptional strength, dimensional stability and rigidity. The maximum panel size currently produced is 10’ x 24’ x 3, 5, or 7 layers. These panels are components of a construction system commonly referred to as “Mass timber construction,” a revival of building taller buildings with wood, greatly reducing the carbon footprint of the
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D.R. JOHNSON – CLT IS A DIFFERENT ANIMAL
project. These buildings have high seismic resilience, and although it’s counterintuitive, a better fire resistance than steel. It is also possible to combine CLT with other building materials in a hybrid system. D.R. Johnson first got involved with CLT in response to a plea for test panels from Thomas Maness, Dean of the College of Forestry and Director of the Oregon Forest Research Laboratory. He had organized an industry meeting in which University researchers, Mass timber architects, and industry producers came together to discuss the market potentials of CLT.
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“They put on an amazing presentation to around 40 industry CEOs,” Valerie Johnson remembered. “It was exciting and looked like an amazing opportunity.” The academic research group was looking for industry support to help kick start the production of CLT in the Pacific North West. The researchers just needed some test panels to get the process going. Having operated a glu-lam plant for many years, Valerie was confident that her team could figure it out. “Several of our people have PhDs in common sense,” she quipped. Under the keen eye
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of John Redfield, COO of D.R. Johnson, the company made 15 test panels that were evaluated and tested by APA against specific criteria including structural performance, design properties, and appearance classifications. A set of standards was issued by ANSI to the industry, and D.R. Johnson received official certification to produce CLT. “It’s a real big deal” Valerie exclaimed, “and the fact that a US manufacturer is a major collaborator makes it a big story.”
Certification is a real big deal, and the fact that a US manufacturer is a major collaborator makes it a big story.
Unique machine design USNR was commissioned to design and manufacture D.R. Johnson’s CLT press. USNR is accustomed to producing presses for the manufacture of OSB, MDF, and plywood, but this is the company’s first press for the manufacture of cross laminated timbers, and it’s a different animal altogether. But the mill had the cart before the horse. D.R. Johnson was getting ready to break ground in Riddle, and USNR had already begun manufacturing the press plates when somebody suggested that John Redfield take a team to Europe to investigate the processes of a more mature market. They took the trip and confirmed the European presses looked a lot like USNR’s design. But there are some key differences.
Above: A worker manually lays up a 5-ply CLT panel just prior to loading in the press. The panel consists of dimension lumber oriented at right angles to each other and then glued to form structural panels with exceptional strength, dimensional stability, and rigidity. Update: DR Johnson has since installed a lay-up machine to automate the layup process. This increases production capacity, allowing the plant to meet increasing market potential.
One difference is the use of compressed air instead of hydraulics. USNR’s CLT press uses pneumatic pressure to produce 10’ wide CLT panels up to 24’ long and 10.5” thick. The panels are assembled using between three to seven layers of cross-laid timbers. Adhesive is applied between the layers prior to the panel entering the press. This press follows a “window frame” design consisting of 16 identical steel frames spaced 18” apart, with each frame having an opening (or “window”) which allows CLT panels to pass through the press. Once the panel has been fed into the press via a set of pop-up rolls, it comes to rest on platens within the press opening. A set of pneumatic cylinders then applies pressure from the sides to ensure minimal gap between timbers within a given layer. Meanwhile, a set of channels carrying 8 large diameter pneumatic hoses is lowered
to rest on top of the CLT panel. Once the panel is configured correctly within the window of the press, the 8 hoses are brought to pressure (typically to 100 psi, though it’s capable of delivering up to 150 psi of pressure). Press time depends largely on the time it takes to lay-up the panel, with a ratio of approximately 2.5:1 (press time to lay-up time). The unique curvature of USNR’s press opening allows it to redistribute stress and withstand the tremendous pressures required to produce APA-certified CLT panels. While most CLT presses utilize hydraulic cylinders to achieve the necessary pressures, the USNR press applies pressure pneumatically instead, thanks to a heavy-duty hose which takes advantage of recent material advancements in the oil and gas industry. This method is robust, extremely costeffective, and more environmentally friendly than the hydraulic alternative. An additional advantage to the USNR design is its modularity – although the press is currently configured to produce 24’ panels, it could easily be modified to any desired length by simply adding or removing window frame segments. “The real genius of USNR’s design is putting the window frames in 18-inch increments,” Valerie said. USNR’s modular press design enables it to be expanded infinitely along its length, giving D.R. Johnson the flexibility to grow their press. “If USNR had not come up with that, I don’t know if we would have ever pulled the trigger because we didn’t know exactly what we needed at the time,” she remembered. “We started out wanting to
The fact that USNR designed it with frames that could be added in a modular way is sheer genius. It was the answer for us.
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D.R. JOHNSON – CLT IS A DIFFERENT ANIMAL
We have historically embraced opportunities presented by new technology and markets. We’re proud that, in collaboration with key partners, we have achieved this milestone.
make an 8 x 16’ panel, then it went up to 10 x 16’, and over time we finally settled on 10 x 24’. The fact that USNR designed it with frames that could be added in a modular way is sheer genius. It was the answer for us.”
Close-up of a 5-ply CLT panel. A 10 x 24’ panel of 5-ply weighs almost 5,000 lbs.
Laura Meeker, USNR Mechanical Engineer on the project explained, “The modularity evolved from the fact that the project began with a smaller press, and when we realized they needed a bigger press, it seemed like a natural solution.”
Market outlook The outlook is bright for D.R Johnson’s CLT product with several jobs in the pipeline. “The market for CLT is growing,” said Valerie. “We are either under contract or in design conversations for over a dozen projects along the West Coast. Demand is there, and we expect other manufacturers to enter the market soon. Competition would give the market more confidence and it would make more supply available.” D.R. Johnson is currently manufacturing CLT panels for the Richard Woodcock Education Center at Western Oregon University. Western Oregon University was the first project to contract with D.R. Johnson and provided the momentum to build the CLT plant and press. The company is also manufacturing CLT for a mixed-use building in North Portland being developed by the Albina Yard Project. In addition to those projects, the company is in design consultations with many other West Coast developers. Combined, the contracted work and project pipeline represents nearly a half-million square feet
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The 5-ply CLT panel being cured in the USNR press.
of CLT panels that may require adding an additional labor shift for the Riddle plant. “Response to the product has been very positive,” Valerie said. “This reaction from the market is showing there are projects ready to design with CLTs. Having a source now where the product can be bought will help build the market for it.” Valerie said the panels can be delivered to construction sites with windows and doors pre-cut. She also noted the company will be installing a Hundegger 5-axis CNC computer-aided panel fabricator early in
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2016. That addition will provide the ability to customize each CLT panel with precise routing and cutting based on the project’s computer-aided design (CAD) files, which can include electrical and plumbing. The customization of panels to precise specifications will further reduce construction timelines and costs. D.R. Johnson expects the market to require this level of prefabrication because there isn’t an economical way to move these panels around on the jobsite to do this work. A 10 x 24’ panel of 5-ply weighs almost 5,000 lbs.
There were a number of things that fell into place to make this a reality, but without USNR we’d be nowhere yet.
How does it compare? One of the biggest ways CLT beats concrete, steel and other alternatives is that it assembles like a Lego set. The material is lighter and easier to handle. In addition, there are a lot less trades on a CLT jobsite compared to those using materials that require a variety of expensive tradesmen. CLT doesn’t require the skilled manpower or the time. It can basically be constructed with a crane operator and someone to handle a screw gun. But it puts a lot of pressure on the mill to get the staging and delivery right. If you can imagine a 4-story building constructed with CLT, they will literally have to keep track of where every panel goes in the construction process. The first truck that leaves the mill should have the first panel needed on the top of the load. It has to be sequenced exactly so they can lift that panel off the truck and put it right into place. They don’t want to be stacking them on the jobsite. Promotional materials on the CLT panels emphasize that the product reduces the carbon footprint of a project, has high seismic resilience and comparable fire resistance to steel. Fire is a major concern, and one reason no doubt, that codes have limited the height of wooden structures. But solid CLT panels do not ignite as easily as 2 x 4s. Even if panels do burn, charring on the outside protects the interior wood, leaving the panel structurally sound. Finishing the panels with wallboard or another material further improves fire protection.
A glu-lam beam at D.R. Johnson under compression. The company uses a USNR Mann Russell RF Gluing machine to cure the glue in large beams and finger-joint stock.
incorporated into building codes. In North America, a more basic understanding of the product is needed first. Valerie says that contractors are currently familiarizing themselves with crosslaminated timbers. Building with CLT panels brings a learning curve that requires adjustments to the traditional bidding process and building methods, since the installation process is as new as the product itself. Valerie suggests that academics and government officials arrange classes and seminars where contractors, engineers and architects can learn how to work with CLT. “There were a number of things that fell into place for us to make this a reality,” Valerie said, “but without USNR we’d be nowhere yet.”
In Europe, cross-laminated timber has been around long enough that standards for fire protection and acoustics are being
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Washington Iron Works
Pressing reset LEGENDARY PRESS LINE IS BACK! USNR's plywood and panel division has installed 250 presses globally for OSB, MDF and other panel products from the Washington Iron Works (WIW) line. Our customers are leaders in the supply of panel products world wide. These presses are monoliths constructed of the highest grade of steel and utilizing specialty processes to withstand the immense forces required for their purpose. Due to this very nature,
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often rebuilding is preferable to replacement as the equipment begins to show its age. USNR recently under took a rebuild project for a WIW press that involved the redesign of some of the components. The result reinvigorated the WIW press line. On the heels of that success the customer has budgeted for several additional press rebuilds.
The customer for this project is a major manufacturer of OSB panels with several plants in its portfolio. Its investment strategy for updating its OSB Washington Iron Works (WIW) press lines includes rebuilding its presses rather than replacing them. This strategy brought the company to USNR to launch a rebuild project for the press at one of its plants. The plant was built in 1996 and fitted with a Washington Iron Works OSB press, the predominant brand of press employed at several more of the company's plants.
Making a case to rebuild The aging press had been the cause of recent reliability issues resulting in structural failure. The rebuild was targeted to reduce maintenance and improve operational reliability, as well as improve the quality of the OSB panel products. The other goal was to gain the technological benefits of the new HAWE hydraulics system that was available as part of the rebuild package. HAWE is a sub-supplier to USNR for press hydraulic systems.
The new hydraulic pump skid is inspected.
We invested a significant amount to reduce the frequency and intensity of hydraulic shock the press must withstand while under load, and the results are proving the value of that investment.
The company's drive to rebuild its OSB presses didn’t start with this one plant. It currently has 7 WIW presses in its OSB group, as well as additional presses for siding production. The company determined that USNR was the best vendor to provide the needed retrofits for its presses. On the USNR supply side, there are several personnel who are veterans of the industry and have been constants with the WIW presses over many years and through several acquisitions of the technology. These include Alan Knokey, Vice President of USNR’s Plywood and Panel division, Pete Volk, USNR Senior Account Manager for presses, as well as several design engineers and service technicians. The HAWE hydraulics package was recognized for its innovation and reliability, and was chosen as a standard component for the WIW press systems going forward.
Rebuild vs. replace It is a huge advantage to rebuild an existing press. Alan Knokey weighed in on some of the key benefits. He explained that
these extreme-load machines typically fail due to high, repeated stress loads which cause key structural members to fail over time. When rebuilding worn out components, the plant realizes all the benefits of a new press with much less capital investment and risk. Choosing the original equipment manufacturer (OEM) to supply upgraded components ensures the new components are manufactured to the exact requirements of the existing machine, while incorporating finite element analysis-driven (FEA) design improvements to reduce stress and increase reliability. This is particularly crucial when taking into account the amount of force required in the equipment manufacturing process. Along with the rebuild of mechanical components, the hydraulic and PLC systems are often upgraded at the same time. New hydraulics and controls advancements have greatly simplified the process, as well as significantly improved throughput and the quality of the finished product. The new hydraulic system has also greatly reduced energy costs for operating the press. Alan commented, “What was unique about this project was the application of new hydraulic technology specifically designed for an OSB application. This technology was first installed on partical board presses with exceptional results. We invested a significant amount of development time and effort to reduce the frequency and intensity of hydraulic shock the press must withstand while under load, and the results are proving the value of that investment.”
Scope of the project The press rebuild included a new crown, heavy-duty jack cylinders, new support beams, new bottom platens, new hydraulic power unit, PLC, and the 4 main cylinders were reconditioned (see page 19). In addition, the simultaneous closing system was upgraded and many routine wear-andtear components were replaced. Because of the extreme loads that presses operate under, the mechanical components of the press are manufactured to exacting specifications. Material certificates are required for the steel used in the
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WASHINGTON IRON WORKS – PRESSING RESET structure to ensure compliance with ASTM International (American Society for Testing and Materials) standards. A variety of non-destructive testing methods were employed to verify material and weld quality. Ultrasonic, magnetic particle and radiographic inspections were performed in critical areas of the crown, jack cylinders, and bottom platen. The major hydraulic system upgrades included replacement of the hydraulic power unit (reservoir, pumps and motors), addition of the Easy Shift Prefill Valve (see page 20) system, and new energy efficient air-to-oil coolers. The outdated PLC and HMI was replaced with Controllogix PLC. The hydraulic system upgrade provided the following benefits: Improved Reduced
press operation reliability press cycle time
Improved
operation control flexibility
Hydraulic simultaneous closing
Reduced
shock and vibration
Reduced
leaks
Reduced
energy costs
This upgrade included supplying 4 new redesigned load arms fitted with rebuilt hydraulic cylinders (rebuilt by customer) that significantly reduce the stress at the inner pivot joint when opening/closing the press. Four new push rods and moving platen brackets with 2 bearings per bracket, effectively reduce stress and increase stability and reliability, as well as contribute to improved thickness control. The press was also fitted with an accumulator upgrade for the simultaneous close that significantly reduced energy costs.
Eliminated
obsolete hydraulic components from the circuit
Improved
Introduced
standard AW68 hydraulic oil
Eliminated
nuisance adjustments of prefill valve shifting with Easy Shift
The new increased-capacity reservoir is designed with baffles to prevent aeration of the oil, eliminating another source for potential shock in the system. The reservoir’s footprint did not change but was designed with an increase in height to accommodate additional volume and higher oil head height.
The new hydraulic pump skid is unloaded.
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oil cleanliness
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Results The press rebuild was completed last year. Subsequently the customer commented, “I am very encouraged by what we had forecasted and what we are seeing. The biggest improvements are in reliability and
finished product quality coming out of the machine. The rebuild has the potential to increase throughput, dependent on all of the support equipment feeding and taking material away from the press. We have yet to test and vet that.�
New press crown
This project was very much a strong, collaborative effort by the three major parties involved – USNR, HAWE and the customer. It is a testament to the cooperation and coordination that are typical when USNR takes on a project, be it large or small. We are particularly pleased to partner with HAWE on this and future WIW press projects.
New simultaneous closing arms
I am very encouraged by what we had forecasted and what we are seeing. The biggest improvements are in reliability and finished product quality.
New bottom platen modules New grade beams New heavy duty jack cylinders
This illustration shows new mechanical components that were replaced on the press.
The new hydraulic filtration skid has been put into place.
One of the 4 huge bottom platens is under construction.
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Press Upgrades
Power play REBUILD AND RENEW YOUR PRESS PERFORMANCE Easy Shift™ Synchronous Valve Control (ESSVC) provides servo valve capability for precisely metering large volumes of oil synchronously through multiple OSB press pre-fill valves. Precisely and synchronously delivering large volumes of oil to the main cylinders on an OSB press improves the ability to manufacture a better quality product, creates a safer work place, and reduces the frequency of oil spillage.
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Easy Shift control converts the very large and difficult-to-adjust and maintain pre-fill valves into precise servo controlled valves by driving the control spool with precision servo motors. Accurately metering large oil flow volumes, despite temperature-induced change in oil viscosity or a temporary lapse in oil hygiene as result of mechanical wear, results in uniform positioning of the moving platen. Reliably positioning the moving platen during the curing process improves board quality.
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Easy Shift has been designed specifically for the harsh environment of the press pit. Prior to the enhanced pre-fill valve control, operators had to frequently climb into the press pit to mechanically adjust limit switches and dash pots to accommodate any subtle change in oil quality or to compensate for valve wear. Easy Shift also eliminates much of the piping and hydraulic connections in the pit reducing the chance of hydraulic leaks and potential for fire.
Power ful collaboration In addition to the Easy Shift Synchronous Valve Control system, USNR has worked with HAWE to develop several other power unit upgrades for new and existing Washington Iron Works (WIW) presses that improve operation and reduce energy requirements. These upgrades improve press operation by mitigating hydraulic shock and reducing the press operating cycle time. In addition, significant energy savings can be realized.
The simplified hydraulic design incorporates improved filtration, proportional pumps, proportional valves, reservoir design, and electrical control of components to improve operation. This approach uses off-the-shelf components that are proven and readily available at reasonable costs. Using conventional proportional valving in combination with standard pressure compensated pumps allows for circuits that are straightforward and useful in providing multiple functions. Proportional controls increase system reliability and reduce maintenance by eliminating shock that is often present, resulting in time savings that can be significant.
Please contact us for more information about upgrades that will improve the performance of your press system.
Benefits of press power unit upgrades: Increased Reduced
production
energy
Simplified Reduced Improved
hydraulic design
maintenance board quality
Press power unit upgrades can be implemented as a complete package or as individual components over time.
PRE-FILL VALVE SHIFTING WITH ELECTRIC ACTUATION One significant component of the new hydraulic system delivered with the WIW press rebuild package is the Easy Shift™ Prefill Valve system. Through coordinated motion control it regulates fluid going to/from each main cylinder, even when the cylinder is actuated by means other than pressurized hydraulic fluid from the power unit being applied to the ram.
Energy
efficient
Reduces
shock
Synchronizes Eliminates Reduces
prefill valves
hydraulic valving
cycle time
Eliminates
pilots from jack circuit
Prior to a rebuild, typically the existing 4 prefill valves are controlled with conventional solenoid valves that are either on or off, and can transition unreliably from one state to the other. The solenoid valves require periodic adjustment to keep the valves shifting smoothly, in time with one another. Better control of prefill valve shift eliminates unwarranted hydraulic shock and constant need to adjust flow controls.
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Press Upgrades
Synchronously shifting the pre-fill valves without hydraulic pressure overshoot or “spike” significantly reduces any undue load imposed on the press structures; columns, jack, main cylinders and piping. Due to the very large nature of an OSB press, an hydraulic spike induced by an out-of-control event such as changes in oil viscosity, oil hygiene or valve wear can lead to ruptured pipes and a large loss of hydraulic fluid. Uniform and precise shifting of the pre-fill valve virtually eliminates unanticipated failure of the press mechanical structure and hydraulic pipes.
We’re sporting a NEW look! UPDATED PRODUCT, SERVICE AND SUPPORT INFORMATION IS AT YOUR FINGERTIPS By now you may have visited our website and noticed we’ve got a brand new look. USNR / Söderhamn Eriksson is excited about the launch of our new website. Our new site features updated product, service and support information. It also provides better access to videos of our products and our systems. We hope you’ll visit often! http://www.usnr.com
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We would also like your feedback to help us make our site a place where you can go for the information and solutions you need to help make your operation thrive. Once you’ve visited our site, please take the brief survey. Thanks for visiting!
New Projects ATCO Wood – Core Drive ATCO Wood Products at Fruitvale, BC has ordered a new hydraulically-powered core drive for its lathe. The new core drive will minimize deflection of the block in the lathe as the block is peeled to small diameters. The new core drive will improve recovery of usable veneer, reduce spinouts at the chucks, and help to maintain consistent veneer thickness throughout the peel. It will accommodate peeling down to a minimum 3” diameter core.
Collums Lumber – ElectraTong Lug Loader Collums Lumber at Allendale, South Carolina, is updating its sawmill with a double unscrambler and USNR’s ElectraTong Lug Loader. The mill produces 1x4” to 2x12” in 16’ lengths.
D.R. Johnson – CLT Press Module The D.R. Johnson operation of Riddle Laminators, at Riddle, Oregon, is expanding its CLT press from 24’ to 30’ with an additional module. This will allow the plant to produce up to 30’ long cross laminated timber panels. You can read about this new USNR product in this issue, starting on page 10.
Jordan Forest Products – 4-Saw Edger with Outfeed Jordan Forest Products at Barnesville, Georgia is investing in a new 4-saw edger with reman head and Flying-V outfeed. The new edger system will be key to managing additional production from a new carriage line the mill is installing.
Lampe & Malphrus – Forano Disc Chippers Lampe and Malphrus at Smithfield, North Carolina have ordered two 66” Forano disc chippers. They will be fitted with J-style infeed spouts that will accept logs up to 17” in diameter and 43-3/4” slabs.
Pollmeier – Carriage System Upgrades The Pollmeier operations at Creuzburg and Malchow, Germany, are investing in technology upgrades for their carriage systems. The Creuzburg mill had recently updated its two carriage lines with the MillExpert G3 optimization platform. Now the Malchow site is following suit for its two carriage lines. As part of these technology updates the mills are also replacing their lines’ existing DynaVision scanners with new ChromaScan 2460 sensors, that
will bolt directly into the existing scan frames. These new generation high speed, high density 3D laser profile scanners are specifically designed for primary log optimization. These upgrades will improve the overall recovery and performance of the company’s carriage lines.
Spanish Trail Lumber – Coastal Planer Upgrade The Spanish Trail Lumber mill at Cypress, Florida is retrofitting its Coastal Planer with new top, bottom and side cutter heads. This will improve the accuracy and throughput for this planer workhorse, affording it many more years of service.
Voma OY – Cambio 460 debarker, CIM 501 infeed The Voma OY mill at Parkano, Finland has ordered a Cambio 460 debarker with CIM 501 infeed. The Cambio 460 is a high speed debarker for small logs. It is paired with the CIM 501 infeed, featuring selfcentering operation via compressed air that allows debarking without any log gaps.
COMPLIMENTARY SUBSCRIPTION For your complimentary subscription to USNR’s Millwide Insider magazine e-mail subscriptions@usnr.com or go to www.usnr.com/Newsletters
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PO Box 310 Woodland, WA 98674
Millwide Insider is printed on recycled paper.
Profile Trevor Wendt is a Major Account Manager with USNR, based at Vancouver, BC. Trevor serves both regional and international accounts for USNR’s Plywood and Panel sector. He represents the full breadth of our panel manufacturing machinery product line. Trevor brings 18 years of experience in the wood and panel products industry, before starting his career with USNR in 2014. He holds a degree in Business Administration from Simon Frasier University.
UPCOMING EVENTS
Trevor says, “I like working with the wide diversity of people both within USNR and our customer base. I enjoy the technical as well as business challenges my customers bring to me. It never gets boring.” His tenure with USNR thus far has brought an indepth focus on the Washington Iron Works press line. Trevor is passionate about hockey, as a player, a fan and now a coach. His favorite teams are Vancouver Canucks (hockey) and Seattle Seahawks (football). During the summer his family enjoys boating on the many beautiful lakes in BC, while his 7-year-old son keeps him busy with sports.
FEB. 2–4 IHLA
MAR. 9–11 HMA
MAR. 22–24 Wood Convention
Indianapolis, Indiana
Fort Worth, Texas
Montreal, Quebec
APR. 6–8 COFI Kelowna, British Columbia