Insider
THE MAGAZINE FROM USNR | ISSUE 41
STAND D65, HALL 25 STAND D08, HALL 26
WAIPAPA PINE GOES FULL TWO THUMBS UP FOR AUTOMATION WITH ITS GRADING WITH THG CARRIAGE LINE
DELTIC TIMBER ADDS COMPARISON SHOPPING VISION SCANNING WITH – WHY THG? THG GRADING LINE
VENTEK SCANNING UPS CLOSING THE GAP WITH RECOVERY, PRODUCTION MILLTRAK 3D AT COASTLAND WOOD
CONTENTS
Millwide Insider ISSUE 41
CONTRIBUTING TO SHARED GOALS More producers than ever are turning to automation to improve their output. Today, automation equipped with high density and high definition vision, laser profile, grain angle, x-ray, strength and moisture measurement, and other advanced technologies, reduces or removes the human factor in many processes. At the same time it provides an abundance of data for more knowledgeable decision making at the management level. We’re proud of the contribution and suppor t to automation that we’ve provided this industry, bringing fresh new concepts to life for the advancement of our shared goals.
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SUBSCRIPTIONS Tel.: 250.833.3028 subscriptions@usnr.com EDITOR Colleen Schonheiter colleen.schonheiter@usnr.com
USNR Woodland, WA: +1.360.225.8267
WAIPAPA PINE With a primary goal to increase throughput, Waipapa Pine took their carriage log breakdown
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from a fully manual process, to fully optimized. They’ve greatly improved their throughput, while recovery gains are a much appreciated bonus.
SÖDERHAMN ERIKSSON Söderhamn, SE: +46.270.746.00 Mariannelund: +46.496.218.00 Mon. - Fri. 07:30 - 16:30 CET www.se-saws.com
DELTIC TIMBER Deltic Timber was looking to update its combination geometric and manual grading line with a state-of-the-ar t automated one. THG was
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chosen for its suitability to the mill’s process,
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and the strong level of trust developed between
Addresses to: USNR c/o Colleen Schonheiter,
customer and vendor.
3550 - 45th Street Southeast, Salmon Arm, BC V1E 1X1
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COASTLAND WOOD INDUSTRIES By synchronizing the veneer production process and upgrading to the latest scanning and optimizing equipment, Coastland Wood Industries was able to increase production while reducing downtime and maintenance requirements.
ROYOMARTIN Nor th America’s largest plywood manufacturing facility selected USNR to supply its new Coe-brand veneer dryer. In the process a new innovation for dryer installation was taken from concept to reality – effectively changing the rules of the game for dryer installation.
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Waipapa Pine
Carriage automation CARRIAGE OPTIMIZATION BUILDS THROUGHPUT, RECOVERY AND SATISFACTION With a primary goal to increase throughput, Waipapa Pine took their carriage log breakdown from a fully manual process, to fully optimized. They've greatly improved their throughput, and recovery gains are a much appreciated added bonus.
We have seen an increase in volume, a higher grade in this volume, and we have cut fewer logs to achieve these improvements. More production, less cost and a better sales mix has given our performance a great boost.
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WAIPAPA PINE – CARRIAGE AUTOMATION
Fitted with both front- and backside Lasar2 sensors, the carriage breakdown process is now fully optimized. The frontside Lasar2 sensor is circled in yellow above, mounted above the log deck.
When we compared functionality and fitness for our operation there was only one way to go. I was very happy knowing USNR sets the benchmark with these systems.
In 2012 Kiwi Timber Protection Ltd (KTP) of Whangarei, New Zealand purchased the assets of a closed sawmill in Kerikeri, NZ, and reopened the site as Waipapa Pine Ltd. Then they set about bringing the primary process up to current standards. Today, the Waipapa Pine operation consists of a sawmill, continuous dry kilns, and timber stacking equipment. The mill’s primary product is high grade framing timber for the new house construction market on the North Island, with some export to the Pacific Islands. The facility currently processes Radiata Pine with a single-shift processing capacity of 130,000 tons of logs annually.
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TYPICAL CARRIAGE LINE LAYOUT Back Lasar2 sensor
Carriage
Slabber
Field of view
Bandsaw
Two Lasar2 sensors are mounted above the log infeed, and are positioned to scan the front and backside of each log once it is loaded on the carriage. With both front and backside scanning the Lasar2 sensors collect dense data from 270 degrees circumference of the log, allowing the MillExpert optimizer to generate a dense 3D model for highly accurate log breakdown solutions. The yellow area above depicts the field of view of the Lasar2 sensors.
Front Lasar2 sensor
Manual sawline challenges The company’s headrig carriage primary breakdown line was installed by the previous owner of the site. The carriage was a fullymanual operation; the operator was 100% responsible to decide what yield to target out of each log. Three years ago the mill installed a slabber on the line. Although it delivered good production results, mill management identified that manually
determining the cuts to make with the slabber added significant time to the process of breaking down a log. With the primary goal to speed up the line, the mill decided to invest in optimization. “We understood that optimization could provide additional benefits, but our main target was to increase production output by reducing the time we spent breaking logs down,” said Grant Arnold, Waipapa Pine Operations Director.
Automating the decision We understood that optimization could provide additional benefits, but our main target was to increase production output by reducing the time we spent breaking logs down.
The mill decided on carriage optimization using USNR’s Lasar2 front and backside scanners. “Scanning as much of the log as possible is preferred for any mill planning to utilize USNR’s optimized whole log breakdown system,” said Dale Bradicich, USNR International Account Manager. “Depending on the mill layout and available space for front and backside sensors, up to 270 degrees of coverage is achievable on a log loaded onto the carriage.”
Grant said, “We considered other vendors and looked at a couple of other installations here in New Zealand, but when we compared functionality and fitness for our operation there was only one way to go.” He continued, “I have also had experience with USNR optimizers in the past, so I was very happy knowing USNR sets the benchmark with these systems.”
Lasar2 scanning Lasar2 is the second-generation laser log scanning technology from USNR. This technology has been used successfully in transverse transport machine centers such as conventional headrig carriages, overhead end-dogging systems and log merchandiser decks, in addition to close-coupled primary breakdown systems such as C-frame carriages and EDLF machines. The scanner produces “radar-type” measurements of the distance from the
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WAIPAPA PINE – CARRIAGE AUTOMATION
Logs queue up at the carriage. Circled upper left is the backside Lasar2 sensor.
The markets here in New Zealand have been very strong throughout 2016 and indications are that this will remain. Like all other sawmillers here, we are working hard to increase production to meet this demand and at the same time lower our operational costs.
sensor to each data point within the field of view, amounting to between 50,000 and 100,000 data points for one side of a log. Using front and backside scanning, a scan image can be created that profiles 75% of a log’s circumference.
Flexible optimization The USNR Carriage Optimization system provides detailed breakdown rules that can be set for each species, grade and fiber class, along with other options including configurable face cut orders, configurable minimum opening face sizes and lengths, half taper, full taper, and no taper options. Multiple adjustable scan zones ensure maximum coverage area and maximum scan density on every size of log. The stop-nloader scan feature allows pre-positioning of the carriage knees to accept the next log, pre-loaded close to the saw line, for faster throughput.
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Installing the system “We are very satisfied with how the project progressed,” said Grant. “Geoff Strang and the group at Skookum Technology (USNR’s agent in the region), Aaron Taitoko and the Tui Technology team, as well as the complete USNR team working on our project, did an excellent job. My Waipapa Pine team grabbed the project with both hands and worked closely with all suppliers to make the project a success.” Monica Thomas, an engineer from USNR’s Salmon Arm, BC location, did the initial log study based on information provided by the mill. The study was instrumental in aiding Waipapa’s decision process. To ensure success, Don Getchell, project manager from USNR’s Eugene, Oregon facility, made the trip to New Zealand for the installation. “Training, commissioning and ongoing support from Don has been to the highest standard,” added Grant.
The mill configures which downstream machine each cut zone is routed through and then optimizes for the log's best opening face.
The mill also sent three representatives from New Zealand to USNR’s facility at Eugene for training. “The support and hospitality shown to us by Chuck Blem and the group we met from USNR was great, not to mention the unexpected bonus of donuts for morning tea,” added Grant. “In all we couldn’t be happier with the level of service we received.”
Exceptional results “One of the biggest challengers we faced was the time that it took to work through the many and varied recommendations we got from industry players with regards to the pros and cons of spending capital on this equipment,” said Grant Arnold. “This delayed the achievement of the excellent results we have seen.” With this optimizer upgrade, all three key production measures in the mill have increased. Run rates have increased by
28%, simply as a result of relieving the operator of breakdown decisions in order to concentrate on loading the log, dogging and driving the carriage. The average time to process a log on the carriage has been reduced by 20 seconds. Sawn recovery has increased by about 3%, and graded recovery has increased by 2.9%. “These results have aligned very well with our business goals,” continued Grant. “Bottom line, we have seen an increase in volume, a higher grade in this volume, and we have cut fewer logs to achieve these improvements. More production, less cost and a better sales mix has given our performance a great boost.” “In the end, we’re very, very satisfied with all that USNR has done for us,” concludes Grant. “Given the success of this install, we plan to move towards optimization in other key machine center areas in the future.”
Looking ahead Grant said, " The markets here in New Zealand have been very strong throughout 2016 and indications are that this will remain. Like all other sawmillers here, we are working hard to increase production to meet this demand and at the same time lower our operational costs." He continued, "As a business we will continue to invest in developing further processing capacity at our Waipapa site as we move through 2017. We have a number of projects due for completion early to mid-2017 and then will move into others towards the end of the year. We are looking forward to these projects being as successful as the USNR carriage optimization project."
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Deltic Timber
Accurate, consistent automated grading VISION SCANNING IMPROVES GRADE OUTTURN, THROUGHPUT
It’s made a significant difference to our operation; now we can run the planer mill one day less than it takes to produce the lumber in the sawmill. We would definitely do this again.
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Deltic Timber was looking to update its combination geometric and manual grading line with a state-of-the-art automated one. Automated grading systems offer consistent accuracy, and they operate at high speed board after board, shift after shift, day after day. THG was chosen for its suitability to the mill’s process, and the strong level of trust developed between customer and vendor.
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Deltic Timber, headquartered in El Dorado, Arkansas owns two state-of-the-art sawmills in the region at Ola and Waldo. Combined annual permitted capacity for these two operations is in the range of 450 mmbf; approximately 200 mmbf is produced at the Waldo facility with 150 employees. The Deltic Timber mills produce 2x4 through 2x12 dimension lumber, timbers, and specialty products including MSR lumber, exclusively from Southern Yellow Pine. The Waldo operation processes both small and larger logs, and includes a sawmill, boilers, dry kilns and planer mill. It recently upgraded its planer mill line with USNR’s Transverse High Grader (THG) system, taking the lumber grading process from a largely manual one to an optimized line.
Investing for success Tommy Downs, Waldo mill manager, commented on the reason Deltic decided to invest in this new process. “We were looking to improve the consistency in both throughput and grade determination, and better control our trimming. We also wanted to remove the manual element and reduce human error.”
Tommy explained that the mill had previously had another vendor's scanner on the line for geometric scanning only. This meant they still required a significant number of manual graders for the visual grading component, and were experiencing difficulty at the planer mill keeping up with all of the output from the sawmill. The management considered other vendors, but selected the THG because of its better fit for the layout of the mill, and the good relationship Deltic and USNR have built over the years.
The new line The new grading line includes a Revolver Lug Loader, THG scanning and optimization system, Grade Projectors, Grade Mark Reader and Multi-Track Fence. The mill's strength predicting machine is positioned at the outfeed of the USNR high speed planer (installed in 2007), and sprays a mark on each piece it determines is a candidate for MSR. As the piece is scanned by the THG, it visually evaluates the piece for all grade characteristics while considering the strength prediction. The THG then makes a grade decision having considered defects such as knots, wane, skip, splits and shakes.
We were looking to improve the consistency in both throughput and grade determination, and better control our trimming. We also wanted to remove the manual element and reduce human error.
The THG’s grade classification is assisted by a sensor positioned at the lumber line end of the scan frame – the pith sensor. This pith sensor visually measures the end grain of the board, calculating its position in the log to very accurately determine the pith location. Together with data collected via high definition 4-sided vision scanning, 4-face grain angle measurements (GrainMap™), and high density laser profile measurements, the pith is modeled down the entire length of the board to very accurately determine knot connectivity within the piece.
TYPICAL THG LAYOUT Grade mark reader
Planer
Fence
Check grader THG Slow down belts
Lug loader
Trimmer Grade Projector display zone (projectors mounted above the flow)
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DELTIC TIMBER – ACCURATE, CONSISTENT AUTOMATED GRADING
Above: A check grader on the line views the projected grade decision from the THG and can downgrade the piece if he warrants.
We decreased our trim loss by around 2%, and we’ve cut our manpower by 3 graders.
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Above: The THG grading system is closely integrated with USNR's WinTally™ sorter management system, allowing the mill a wide range of capabilities to manage its sorts and its production.
The Grade Projector system is unique, and developed by USNR. The Grade Projectors are mounted above the flow and project each board’s grade onto the surface of the board as it passes by the check grader. Tommy said, “It works really well. It helps me because when I’m on the line I can see what the THG is grading each piece. I really like that feature.”
than it takes to produce the lumber in the sawmill. We would definitely do this again.” Tommy noted that, while this was the beta site for proving the THG’s efficacy on SYP, he always felt USNR was fully committed to the project. The relationship remains solid, with Deltic looking at more new USNR equipment to outfit the mill.
Learning the ropes
Reaping rewards The results the mill is achieving are well received. Tommy commented, “We decreased our trim loss by around 2%, and we’ve cut our manpower by 3 graders. I can’t stress enough the improvement in consistency of the flow at the planer mill. The machine doesn't get behind. With the THG running we have increased our throughput capacity by about 4000 ft./hour.” Reluctant to share grade uplift percentages, Tommy did express that the mill is achieving good results. He continued, “It’s made a significant difference to our operation; now we can run the planer mill one day less
Training for advanced optimization systems is crucial to achieve the greatest return from the investment. In Deltic's case, four
I can’t stress enough the improvement in consistency of the flow at the planer mill. With the THG running we have increased our throughput capacity by about 4000 ft./hour.
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DELTIC TIMBER – ACCURATE, CONSISTENT AUTOMATED GRADING
Above is a generic screen showing a dry mill grade optimization system processing Southern Yellow Pine. USNR's grade optimization for THG, LHG (transverse and lineal dry mill grading) and BioVision (green mill grading) offers a wide range of flexible features to organize the data for optimum product management. employees from Waldo attended training at USNR’s Salmon Arm, BC training facility, and this was followed up with extensive training at the mill once the system was operational. In house training can also be performed in cases where mill personnel simply can't get away for off-site training. Tommy notes those individuals who were key to the success of this project; Mike Russell, Quality Control, was hands-on from the start and still oversees the THG’s
operation, as well Kent Streeter, VP of Wood Products was instrumental to the project, as was Tommy himself. Now that the grading line project is behind them, Tommy explained that Waldo is continuing to evaluate ways to improve all of its processes. The bottleneck has been pushed further up the line now that the THG has significantly increased the throughput of the planer mill.
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Optimized Grade Sawing
MOF+ Mode
BOF Mode
Turn Your Carriage into a Profit Center. MillExpert™ Optimization software uses True Shape 3D scan data to consider millions of solutions based on log grades, surface features, and user-defined product definitions. You specify the wane limits, grade zones, and real dollar values and the optimizer calculates the most valuable solution for every log loaded on your carriage. USNR’s MillExpert™ optimized log carriage system provides highly accurate opening faces and will model any downstream machinery including curve sawing machines, resaws, edgers, and trimmers. This increases throughput and ensures the best fiber utilization and recovery for your sawmill. Three advanced cutting modes including MOF+, BOF, and Optimized Grade Sawing, give the flexibility to get the most from your resource. MOF+ and BOF modes improve consistency and maximize grade out, giving you more control over your product mix to meet market demands. Optimized Grade Sawing is the industry’s most advanced yet easy to use system available. Contact us to discuss putting this technology in your mill.
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A & J Scott
Setting output records INCREASED CAPACITY, REDUCED MANPOWER Our decision to invest in our sawline was based on the need for higher timber recovery, both in terms of volume as well as value, lower mechanical and operational downtime and the need to upgrade older machinery with new technology.
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A & J Scott Ltd. is a large, independent player in the UK sawmilling industry. In early 2016 the company commissioned a new primary breakdown line and edger line supplied by Sรถderhamn Eriksson / USNR, at its Mill 7. Production capacity has significantly increased, and today the company is setting output records as a result of its vision toward excellence, and its major investment in the business. The company aims to increase its overall output for 2017 by over 15%.
Millwide Insider | ISSUE 41 | www.usnr.com | www.se-saws.com
The reducer unit is installed. It will be upstream from the quad bandsaw.
Above: The auto-rotating log turner, side-shifting LogPos infeed, reducer quad bandsaw and board separator are shown in place.
A & J Scott is a strong family-owned company that was established in 1960. It operates from its original site located in Northumberland. Employing over 100 individuals, it is a very important employer in the area. Over the last 18 months it has invested in a large upgrade to the sawline with technology supplied by Söderhamn Eriksson / USNR including a new mill infeed, 3D optimization with LogPos log infeed and a bandsaw reducer quad. The company also installed a new Catech 400 optimizing edger line. Söderhamn Eriksson / USNR is proud to have been a supplier-partner to this outstanding producer for many years, and most recently supplying a Bruks drum chipper line at this mill. Robert Scott, Managing Director, recently commented on the project. “Our decision to invest in our sawline was based on a number of factors. These included the need for higher timber recovery, both in terms of volume as well as value, lower mechanical and operational downtime and the need to upgrade older machinery with new technology.”
“We selected Söderhamn Eriksson / USNR equipment because it has an excellent reputation within the industry. The proposal put together by their team fit our needs well and we were confident that it would deliver what we needed.” In addition to 3D optimization and PLC controls, the supply includes the following: Automated log rotation conveyor LogPos positioning log infeed Reducer Quad bandsaw unit Board separator Merry-go-round processing upgrade Catech 400 optimizing edger line with 3-saw edger sawbox With its new equipment, the complete sawline and edger line requires only a single operator. The operator is located in the edger control room so he is completely out of the line of sight of the sawline. While cameras are positioned to provide monitoring of the sawline from the
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A & J SCOTT – SETTING OUTPUT RECORDS
The side-shifting LogPos infeed and reducer quad bandsaw.
We selected Söderhamn Eriksson / USNR equipment because it has an excellent reputation within the industry. The proposal put together by their team fit our needs well and we were confident that it would deliver what we needed.
control room, the operator must rely on the equipment to run automatically. Mill management is pleased with the result of the investment, enabling the company to start 2017 with an all-time record output. A & J Scott was recently visited by the Conservative MP for Berwick-upon-Tweed, Anne-Marie Trevelyan as part of National Apprenticeship Week in the UK. The theme of the week was 'ladder of opportunity' celebrating the achievements of apprentices over the last decade and highlighting the many apprenticeship routes available for
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young talent, from traineeships through to higher and degree apprenticeships. A & J Scott Ltd is proud of the company’s apprenticeship scheme providing training to a very high standard and has done so for many years. Anne-Marie Trevelyan is a Vice Chair of the All-Party Parliamentary Group (APPG) on Forestry where, together with other MP’s, the group works toward promoting the UK’s forestry sector. In the UK one of the major voices for the forestry and wood sector is Confor and they work together with AnneMarie Trevelyan as part of the APPG. Confor is a not-for-profit organization that works very hard to promote the timber industry at all levels, including governmental. Robert Scott said, “This latest investment will increase our output of high quality fencing products to complement the increased range of railway sleepers and landscaping timbers we are producing. It's a great feeling to start the new year by bringing the upgraded production facilities online, and we are looking forward to another strong year ahead."
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Anne-Marie Trevelyan, Vice Chair of the governmental APPG, visits A & J Scott to view the new lines in action.
It's a great feeling to start the new year by bringing the upgraded production facilities online, and we are looking forward to another strong year ahead.
Renewed focus for Germany
Q& A MI – What do you see in the near future for the industry? EM – Our customers made a lot of investments in the industry during the boom years in the late-1990s and mid-2000s. Then the global financial crisis struck, so investment has been low in the past ten years. I think the market is ready to invest as there is some machinery that needs to be changed. I also think that the market is open to new solutions. USNR’s lumber handling equipment such as the Virtual Lug Loader, the fast-stacking machines and the Multi-Track Fence are very interesting. The scanning solutions are also exciting and can be of great value for all kinds of mills.
ECKART MÜLLER: ACCOUNT MANAGER Söderhamn Eriksson / USNR is pleased to announce the appointment of Mr. Eckart Müller as account manager for its interests throughout German-speaking Europe. With more than 25 years of experience from selling sawmill equipment, Mr. Müller is a wellknown expert to many people in the business. Now he takes on a new challenge as Söderhamn Eriksson / USNR increases its presence in these markets. Mr. Müller represents our sales efforts from his base in Massenhausen, Bavaria. Born in Cologne, Mr. Müller took his first steps into the industry through the University of Applied Sciences (Fachhochschule) in Rosenheim, where he received a Diplom-Ingenieur (FH) in wood engineering in 1990. As a part of his studies he spent time in the US at a furniture company. When he is away from his work, Mr. Müller spends time with his wife, Ingrid, and their three children. His family enjoys sailing and skiing, and he and his wife like to tour around in the Alps on their two BMW motorcycles. They also run marathons together, making for a very active lifestyle.
MI – Being new to our company, are there products you are surprised to find in our catalog?
EM – I was not expecting to find Cross-Laminated Timber (CLT) technology. This is a rising market, and I think there are good opportunities for our machinery to fit in.
MI – Which challenges do you see bringing a brand to this market that has typically offered more North American designs?
EM – Many customers have asked me whether we use the imperial or metric system in our machinery. The answer is simply that all equipment marketed in Europe will comply to the metric system. We are expecting that some of the North American designs will even be built in our Swedish facilities - in fact, we are already doing this.
MI – Ligna is coming up in May, what are your expectations? EM – The Ligna show is one of the most important platforms in our business. My job until then will be to tell everybody that we are in Germany to stay and that we will be at Ligna. I am sure that we will show some interesting solutions, both for large and smaller mills. All sawmill owners will have to stop by at our booths and hopefully they will bring home some of our ideas.
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Södra Wood Värö
Reducing trim loss MULTI-TRACK FENCE: A PROMISING INVESTMENT FOR THE FUTURE
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Christer Carlson, left, from Söderhamn Eriksson / USNR discusses this successful project with David Herbertsson and Mattias Sundholm of Södra Wood Värö.
When the old fence no longer met the high quality standards of Södra Wood Värö, one of Sweden’s biggest sawmills, they installed a MultiTrack Fence from Söderhamn Eriksson / USNR. It was a promising investment for their future. Good sawmillers know, the further on in the production chain, the higher the costs for inaccurate cuts. That was a major driver for the Södra Wood Värö plant when they set out to reduce trim loss at their trim line. After investigation, they quickly realized that there was big money to save if the accuracy of the trimming was improved; reducing trim loss is significant to enhance recovery in both volume and value.
Our requirements were a decrease of faulty trim cuts by 0.4%. With our production volume it means several hundred thousand dollars a year in savings.
"Our requirements were a decrease of faulty trim cuts by 0.4%. It may not sound like it is a big figure but with our production volume it means several hundred thousand dollars a year in savings," says Mattias Sundholm, production engineer. Mattias continued, "The production line runs at full speed now. We are satisfied that our flow targets are being met, and probably even more so."
Service close at hand One of the reasons for choosing Söderhamn Eriksson / USNR as a supplier was the need for access to local service and support. "We are very happy to have a reliable Swedish industry supplier in this region," says Mattias Sundholm.
Manufactured in Sweden The Multi-Track Fence has earned a solid reputation for its accuracy and reliability in North America. The machine that was installed at Södra Wood Värö is built by Söderhamn Eriksson in Sweden. It fully complies to the metric system and is equipped with components that are familiar to the European market.
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SÖDRA WOOD VÄRÖ – REDUCING TRIM LOSS
The paddles are pre-set by being directed into different tracks.
Smooth project The installation took place the last weekend of November 2016 and ran completely as scheduled. Christer Carlson, sales manager at Söderhamn Eriksson / USNR, related, "This sawmill is big and spacious. We drove in with the loader, lifted out the old fence and dropped into place the new Multi-Track Fence, and aligned it. Then we connected it to the existing drive gears before the electricians took over. Mattias Sundholm agrees, "This is one of the best projects that we’ve had here."
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The final adjustment, as the rest of the machine, is completely electric.
The production line runs at full speed now. We are satisfied that our flow targets are being met, and probably even more so.
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Multi-Track Fence
Industry's #1 choice OVER 115 SOLD GLOBALLY SINCE 2010 Our Multi-Track Fence is proven to be the market's top solution for high speed mills. Introduced in 2010, there are now more than 115 units operating in green and dry mills all over the globe. The Multi-Track Fence is a cost effective solution for mills that require a rapid, highly accurate fencing system for the most demanding applications. It is an excellent choice for high-speed optimized applications offering infinite resolution, and guaranteed at 0.1” (2.5 mm) accuracy. The Multi-Track Fence allows wider lug spacing at higher speeds, with less critical timing than other rotary fence models. It operates without any air or hydraulics; allelectric actuation is easy to maintain. The MultiTrack Fence is designed to retrofit into existing 3-stage fence locations.
The Multi-Track Fence uses moving board bumpers to position the boards, and this allows several lug spaces for boards to come to the bumpers and settle into a fixed setback location prior to leaving the positioning system to be trimmed. The result is highly accurate, infinite board positioning, and often higher speeds. The all-electric design eliminates system leakage and maintenance associated with air or hydraulics actuation. Operating costs are reduced with less maintenance required and lower energy consumption.
Features Available
in 12” (305 mm) and 24” (610 mm) setbacks; push or pull back configurations
Bumper
accuracy +/- 0.1” (2.5 mm)
Speeds
over 200 LPM on dimension applications
Non-critical
timing; no air cylinder cushions to tune
Simple
PLC control
Electric
design reduces operating costs
No
fussy brakes internal to moving board bumpers
Easy
access for maintenance
Contact us for information, +360.225.8267 or visit our website.
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We track our numbers closely and have realized a significant energy savings from ADEC. I couldn’t be happier with its performance. – Dave Powers, Mill Manager, Coastland Wood Industries
ADEC Optimizes Dryer Performance. ADEC maximizes thermal efficiency, minimizes exhaust flow and improves veneer quality through exceptional humidity control.
The most critical costs in the veneer drying process are thermal energy requirements to the dryer, and treating the exhaust. The patented Automatic Dryer Exhaust Control (ADEC) system significantly reduces the cost of drying veneer by decreasing energy consumption at the dryer and lowering exhaust treatment expenses. This, coupled with the resulting productivity gains and improved veneer quality, makes the ADEC system a powerful tool in optimizing your veneer drying operation. Contact us to learn more.
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Coastland Wood Industries
Smoothing the flow SYNCHRONIZED VENEER SCANNING AND HANDLING EQUIPMENT INCREASES RECOVERY FOR COASTLAND’S VENEER MILL By synchronizing the veneer production process and upgrading to the latest scanning and optimizing equipment, Coastland Wood Industries was able to increase production while reducing downtime and maintenance requirements. www.usnr.com | www.se-saws.com | ISSUE 41 | Millwide Insider 23
COASTLAND WOOD INDUSTRIES – SMOOTHING THE FLOW
We're seeing better uptime and an increase in recovery for sure. On a volume basis, we were able to speed up the line by 20%.
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In late 2016 USNR acquired the Ventek Inc. business, bringing with it new, complementary technologies to add to the USNR por tfolio. Ventek had recently completed, or was in the process of completing, several successful projects. Integral to the work Ventek has done for many years is its relationship with Elite Automation Ltd., based in Burnaby, British Columbia. Elite provides primarily the PLC controls segment for Ventek products and projects. This ar ticle relates a project by Ventek and Elite, that added much value to Coastland Wood Industries' veneer operation with improvements in recovery, capacity and uptime.
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Canada’s rainy Vancouver Island is known for its lush stands of Douglas Fir, which yield very high-quality veneer. The first steps in processing the local fiber are performed by Coastland Wood Industries, which operates three veneer lathe lines at the company’s 10-acre Nanaimo BC mill. The mill handles about 900,000 m3 of logs per year to produce veneer in thicknesses ranging 1/8,” 1/7,” and 1/10,” amounting to the equivalent of approximately 450 million square feet of 3/8” veneer per year. Seventy percent of the product is dried and the rest is sold green. Coastland sells 95% of its veneer in North America, with the balance sold into Asia. Because of space constraints in Nanaimo, drying and further processing of the veneer is done at the company’s Delta, BC plant on the mainland. This creates some transportation challenges which add to product cost. Hence, it is critical that the Nanaimo operation run as efficiently as possible. “In order to overcome our transport costs we’ve got to be that much better at what we do,” said Doug Pauze, General Manager for Coastland’s veneer manufacturing operation.
The Upgrade Over the last couple of years, the drive to improve their production processes at Nanaimo caused Coastland’s management to invest in an equipment upgrade that included installation of: Ventek Multi-Point Diverter System
(MPDS), replacing two older-technology vacuum diverters Ventek MPDS interface conveyors to
strip trays Above: The operator monitors the flow of veneer through the scan frame at the NV4g green veneer scanning system.
Ventek NV4g Green Scanner & grading
system to replace Coastland’s earlier version, New Vision 3000 Ventek GEM moisture meter installed at
the clipper, replacing an older moisture meter that was at the infeed of the stacker. This new GEM system allows Coastland to make clip size adjustments based on moisture content
We wanted the best technology to reduce downtime and increase efficiencies. It was natural that we check out Ventek's newest equipment, and it has proven to be the best available for our needs.
New lathe spindle, primary tray and
strip tray controls, motors and drives The NV4g scanner and GEM moisture meter were installed in the first phase in 2015. The spindle and primary tray controls were installed in the second phase in early summer 2016. The installation of the MPDS and strip tray controls were the last phase, completed in August of 2016.
Why Ventek / Elite? “We wanted the best technology to reduce downtime and increase efficiencies,” said Doug. “We have had good experiences with Ventek products in the past. We’ve always had a Ventek green scanning line, and we have Ventek equipment for dry veneer scanning at our Delta operation, so it was natural that we check out Ventek’s newest equipment, and it has proven to be the best available for our needs.”
The process The veneer production process at Coastland starts with sorting, cutting and debarking the raw logs, followed by peeling the veneer to the desired thickness on one of three veneer lathes. The veneer is then clipped to produce sheets. Veneer destined for plywood is directed to stacker #1 (5 bins). Low grade sheets destined for post and beam construction are directed to stacker #2 (also 5 bins). Veneer quality decisions are made automatically on a sheet-by-sheet basis by scanning/grading systems that monitor the process.
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COASTLAND WOOD INDUSTRIES – SMOOTHING THE FLOW such as PLCs or motor drives can be incorporated easily into the system in the future without concern for the issues of dealing with proprietary elements.
The install “The project went seamlessly from our perspective,” said Doug Pauze. “It’s probably one of the easiest projects we’ve ever done. The only real challenge was physically getting the diverters equipment into our space-constrained mill. We had to cut a hole in the middle of the mill roof and lower it in with a crane.”
The Multi-Point Diverter system downstream from the NV4g green scanning system, diverts scanned veneer to the appropriate destination - strip tray or clipper table.
Specific improvements Ventek’s goal for the Coastland installation was for each veneer line, from the lathe to the clipper table, to act as one unit, much like a paper machine. This involves synchronizing the speed of the various system components to run in lock step, which in turn minimizes ribbon breaks due to mismatched peeling and tray control process speeds. Rather than running the lathe at full speed and then stopping it to wait on the clipper, the lathe is run just fast enough to keep the clipper full without stopping and starting as often. The smoother operation reduces downtime and maintenance requirements. It also eliminates ribbon breaks, which are common in systems that run asynchronously. Combined with a
The project went seamlessly. It's probably one of the easiest projects we've ever done.
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better-controlled and well-tuned catch-up tray system, the synchronized processing allows the lathe to send more veneer to the clipper. Gaps in the clipper operation are held to a minimum, while clipping decisions made by the Ventek NV4g lead to more recovery, compared to older systems that may cause salvageable veneer to be trashed prematurely. The same principle goes for the strip tray controls, which are designed to operate just fast enough to maintain a constant flow of material. The new controls require less operator intervention and increase tray capacity by diverting the trash veneer at the MPDS, and by keeping tight positional control over veneer sheets as they pass through the system. The new moisture-sensing equipment added to the line enables better and more consistent moisture sorting for drying gains at Coastland’s dry-end plant at Delta, BC. The operator interface for each line is designed so that it is extremely simple to tune and dial in adjustments such as belt speed and veneer quality change. Because the design is highly modular and uses nonproprietary components, new technologies
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“Then, once the MPDS was in place and the crane left the site, we discovered an alignment issue,” said Chris Van Ackeren, Ventek account manager. ”This had to be field modified and could have been a show stopper, causing delays to a very tight install and shut down schedule, but Jason Tracy of Ventek and the crew from Coastland corrected the problem overnight so that the startup took place right on schedule.” Training on the system was handled by Ventek’s installation techs and engineers following start up, and the Coastland team took ownership very quickly.
Results The operating results of the line upgrades have been impressive. “We’re seeing better uptime and an increase in recovery for sure,” said Doug. “On a volume basis, we were able to speed up the line by 20% and get higher capacity. We definitely met every goal that we were trying to achieve, and then some.”
RoyOMartin
Installation innovation GROUND BREAKING INSTALLATION PROCESS FOR AMERICA'S TOP PLYWOOD PRODUCER North America’s largest plywood manufacturing facility selected USNR to supply its new Coe-brand veneer dryer – a high production 6-deck system that outperforms others on the market. In the process a new innovation for dryer installation was taken from concept to reality – effectively changing the rules of the game for dryer installation.
I told Alan we had to come up with a way to tear the dryer out and put the new one in in 3 weeks.
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ROYOMARTIN – INSTALLATION INNOVATION When the largest plywood manufacturing facility in Nor th America goes looking for a veneer dryer supplier they need look no fur ther than USNR. This was proven to be the case with the first Southern Pine 6-deck jet veneer dryer installed at Chopin, Louisiana. With a successful project behind them, a few weeks after star t-up RoyOMar tin purchased a second, identical 6-deck dryer. RoyOMartin's Chopin plant is one of the most advanced plywood manufacturing facilities on the continent. In addition to the two new 6-deck dryers, the site utilizes a USNR high speed lathe system and two 4-deck USNR dryers. Chopin produces a wide array of panel products for a myriad of applications; siding, sheathing, underlayment, beaded decorative panels, concrete forming, radiant barrier panels, and more. It also produces top quality furniture-grade plywood and panels.
Staying with a winner In September 2010 issue of Millwide Insider we told you about USNR’s Coe 4-deck jet veneer dryer that was installed at the Chopin facility. At the time, Jonathan Martin, chairman and CEO of the company, commented, “We’ve been very, very pleased with the production capacity of the machine. We reached the machine’s capacity within a week (of start-up) with almost no issues, which is unheard of.” In late 2011, with markets on the upswing, Jonathan determined it was time to invest once more in expanded veneer drying capacity. “We were very pleased with dryers 4 and 5 which we bought from Coe. We had seen the results of the increased dry veneer capacity and improved quality of veneer, so we wanted to stay with the same manufacturer.” This latest veneer dryer project marks the 3rd Coe dryer installed at the Chopin complex, and speaks to the unwavering confidence the company holds for the Coe dryer technology.
New dryer design This first 6-deck jet veneer dryer in the southern pine industry was commissioned late in 2012; it is the 4th 6-deck dryer built by USNR. The Chopin dryer includes 18 drying sections (144’) long and is heated
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with thermal oil. Unique USNR-designed pressurized fan shaft seals effectively keep the plant environment exceptionally clean. The Chopin plant also invested in the proprietary Automatic Dryer Exhaust Control (ADEC) system. ADEC allows automatic control of the total dryer exhaust volume, and ensures efficient production and maximum veneer quality. Cooler Pressure Balance and Veneer Temperature Control work together at the end of the process to ensure uniform temperature is maintained as the veneer exits the dryer, minimize pitch build up and maximize thermal efficiency.
Maintaining market momentum Jonathan Martin was determined to take every advantage of the profitable market conditions, and looked for inspiration to achieve his goal to maintain the company’s momentum in the market place. Often the largest cost a producer bears when investing in a new veneer dryer is the outage (production down time) required to demolish the old dryer, erect and commission the new dryer in its place. Jonathan found his inspiration and took his idea to Alan Knokey, VP of USNR’s plywood and panel products.
In any production plant the cost of under capacity or lost production is huge, so anything that can be done to minimize taking machinery out of service is beneficial to us.
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We were very pleased with dryers 4 and 5 which we bought from Coe. We had seen the results of the increased dry veneer capacity and improved quality of veneer.
Jonathan explained. “We’ve experienced a very good plywood market for the past 18 months, so one of the major costs is taking that much production (about 1/3 of our dry veneer production) out for an extended period of time. I told Alan we had to come up with a way to tear the dryer out and put the new one in in 3 weeks.” He went on, “I’ve seen this done with major pieces of equipment in chemical plants. We build it off line, we roll it into place, we hook up the hot oil and electrical, and away we go.” Alan and the USNR engineering team were very excited about this new concept and the challenge it presented.
A new challenge Clint Spangler, engineering manager for USNR’s plywood and panel division, was charged with directing engineering efforts for the project. His initial reaction when presented with the idea was, “That’s a pretty big piece of machinery but there’s no reason that would prohibit us from doing it.” The opportunity was enticing, and he commented, “Our biggest challenge was designing the dryer in such a way that we would not pull it apart when we moved it into position. Dryers are typically erected in place, so this project involved designing a means of supporting the dryer for the initial assembly, for rolling it into position and for the final positioning.” Randy Bullion, mechanical engineering manager, designed the rail system the dryer was assembled and transported on. “The rail system needed to be free of abrupt changes in elevation and width. It was designed using various sizes of beams to account for changes in floor elevation.
Structural steel can have variances not only between sizes, but also within the same size and weight depending on where and when the beams were produced.”
Game-changing process A typical new dryer installation can require 18 weeks of downtime; with this new concept the Chopin plant outage was less than 3 weeks. “In any production plant the cost of under capacity or lost production is huge, so anything that can be done to minimize taking machinery out of service is beneficial to us,” said Jonathan, adding that about 95% of the project went off without a hitch. From USNR’s perspective, the biggest challenge was, in Alan Knokey’s words, “Getting up the courage to make the first pull.” Dave Brown of BMI Contractors was contracted to erect the new dryer, demolish the existing dryer, and tow the new dryer into position.
Team effor t BMI Contractors, based at Salem, Oregon, has 30 years of history working with Coe Manufacturing and USNR. Dave Brown, president of BMI, said, “The relationship between our companies has always been symbiotic in that we help each other succeed. BMI works to provide trouble-free installations, offering a depth of experience and knowledge of individual machines as well as overall production flow. For us a win is when everybody is happy and with USNR equipment we are confident every project will be a win.” He went on to explain that BMI has installed 2 new USNR veneer dryers at Chopin, and both projects were winners. He also commended the Chopin mill personnel, “The RoyOMartin personnel are very knowledgeable and look for ways to improve the project. They have always treated us as part of the family.”
Above: The new dryer is erected off-line, while the old dryer (not shown) is disassembled.
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ROYOMARTIN – INSTALLATION INNOVATION Dave commented that every project presents its own challenges. He said, “USNR has always had support in place to reduce or eliminate the effects of these challenges. I have long believed that problems are part of the job; it’s what we do with them that separates us from the crowd. Fortunately, we find this same attitude with USNR.”
Moving day
Above & below: Preparations are underway to tow the new dryer into place after the old dryer was removed. The complete process to erect the new dryer, disassemble the old dryer and move the new dryer into place happened in just 3 weeks.
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He went on to explain that the major differentiator with this project was simply the magnitude of the dryer to be moved. “Other pieces we’ve moved rarely top 100,000 pounds. The new 6-deck dryer tipped the scales at nearly 1 million pounds.” After discussion with all parties involved he decided to opt for an abundance of horsepower; they mounted a large winch to the floor of the mill to provide the moving force. He said they expected the dryer would take several hours to move the 300 feet into position, but the job was done in under 45 minutes.
Our biggest challenge was designing the dryer in such a way that we would not pull it apart when we moved it into position.
Dave’s team has lots of experience erecting wood processing equipment. Besides the savings in outage time for the mill, he explained that this new construction process allows more time for quality checks and inspections with less timeline pressure. Improved safety is also a huge advantage. “When a dryer is demolished and a new one built in place, production is curtailed and so getting back to operation quickly is critical. When time pressure mounts the chance of injury increases.”
Above & below: The project is complete and the dryer is performing beautifully, while preparations are underway for the next dryer of its kind to take its place.
New project on the horizon With the success of this project behind him, Jonathan has contracted with USNR for another dryer. “We have another 6-deck dryer going in in the fall, and it will be assembled off-line and towed into place just like the last one.” Jonathan has a lot of experience with Coe equipment and working with USNR. “It’s been a very fruitful working relationship. I’ve done business with USNR for sawmill equipment and plywood equipment for 40 years.”
We have another identical 6-deck dryer going in in the fall, and it will be assembled off-line and towed into place just like the last one.
The ability to replace existing dryers by towing the fully preassembled new dryer into place significantly reduces the cost of a new dryer installation. This new process will undoubtedly change the face of many future veneer dryer projects, as other processors recognize the opportunity for savings in time and money. USNR is honored to have been entrusted with bringing Jonathan Martin’s vision from concept to reality.
Scan the QR code to view a time lapse video of the dryer construction at the Chopin plant, or go to: http://vimeo.com/65912061
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PO Box 310 Woodland, WA 98674
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PROFILE Tracey Mitchell is an Account Manager based at Perry, Georgia. With a strong record in the solid wood processing industry, Tracey brings a host of skills and a powerful work ethic to his new role at USNR. He will initially manage accounts in Georgia, Florida and Alabama. Tracey gained 20 years of operational experience during his tenure at the former Tolleson Lumber Company (now Interfor) at Perry, GA. While at Tolleson Tracey held supervisory roles managing the green end, dry end and dry kilns.
UPCOMING EVENTS
Tracey is looking forward to a new role on the supplier side. “Because I have worked in the production side of the business, I’m excited to be a fresh set of eyes to bring a solution for whatever problem customers are experiencing. Chances are over the years I have encountered similar issues.” Tracey enjoys time spent with wife Kathy, and two sons aged 8 and 5 years. He also has a 19 -year-old daughter who is in college. Tracey is very active in his church, he loves to hunt, and to run his portable sawmill. He says, “I grew up in Colorado, so I like to go and visit my family whenever I can.”
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