Better data yields better decisions

Hunt Forest Products

Better data yields better decisions

VENTEK SCANNERS AUTOMATE VENEER GRADING PROCESS, IMPROVE DECISION MAKING

Management at Hunt Forest Products found better optimizing solutions in a new generation of scanning equipment. By upgrading the Pollock, Louisiana mill’s green-end with a new NV4g scanner, and two GSc2000 scanners at the dry end, Hunt was able to automate the clipping and grading decision process, bringing consistency and improved recovery to the company’s production across the panel manufacturing process.

When a new generation of Hunt family members took over control of the company in 2015, the new managers recognized that the Pollock plant’s yield could be increased with a technology upgrade to automate the veneer grading process.

Hunt Forest Products LLC is a family owned wood products company founded in 1978. The company’s Pollock, Louisiana plant manufactures veneer and plywood, mostly from southern yellow pine. The Pollock plant runs 24/7, employing about 290 people. The mill’s capacity is 250 million square feet of 3/8” plywood and veneer annually, produced in various thicknesses according to market needs and the quality of logs being processed. Typical of many veneer operations, landscape timbers are also produced as a byproduct of the lathe operation. Most of the company’s production is sold domestically in the U.S.

Gaining insight

Previous decisions for the grading of veneer both at the green and dry ends of the process, were done manually. “With manual grading, the consistency wasn’t there,” said company President L. Richard “Richie” LeBlanc. “We needed to better understand and get control of our processes. We felt that automating the grading process would help us determine the best products that we should be producing for our market.”

The first scanner installed at the green end of the veneer process was the NV2000, manufactured by Ventek* at Eugene, Oregon. This system served the mill well for several years. When Ventek launched newer models with improved capabilities, mill management decided it was time to upgrade with a new green veneer scanner, and add a dry veneer scanner at the dry end of the mill to further improve the process.

*The Ventek product line was acquired by USNR in 2016

I'm extremely satisfied with the overall results that we're seeing from the data out of these systems. The information is allowing us to make much more effective decisions in the dayto-day operation of our plant. We've been able to refine our product mix and improve recovery.

The NV4g scanning system identifies the trash defects, fishtail (good wood on left or right half) and strip until full sheets can be made, in the green area of the plant. It works with the moisture detection system to also identify areas with higher moisture content so the sheets can be sorted accordingly before drying.

Hunt Forests has two GSc2000 scanners operating side-by-side. The GSc2000 performs process data collection and interfaces to the plant’s remote management information system.

The GSc2000 provides better than 95% grading accuracy for the dry veneer. Because the system is automated, grading decisions are made with a higher degree of consistency than before.

Below: The GSc2000 screen shows the sheets as they come out of the scanner with their grade solution. The enlarged sheet data explanation:

• DX (the grade assigned)

• > New Grade D (the next higher grade)

• Automatic Limit (the next higher grade was automatically declined - too many defects)

• W= 49.80 (sheet width)

• L= 100.82 (sheet length)

• P=0, M=0 (user defined data, in this case patch counts)

Why Ventek/USNR?

“Ventek is a well-respected supplier to our industry,” said Richie. “Our plant manager, Walter Wagner, had previously worked in facilities where Ventek scanners were installed. We made the decision largely based on Walter’s experience and on information that the Ventek team provided.”

Making progress

The 4th generation Ventek NV4g green veneer scanning system uses the latest machine vision technology coupled with neural network classification algorithms, to accurately and reliably optimize green veneer clipping solutions. The system optimizes clipping taking into consideration information provided about downstream processes, the plant's product requirements, and grade parameters. Capable of a precise scanning measurement resolution of .060 in., the system uses true-color LED lighting for long-life operation and better color discrimination. In particular, the new lighting system improves light wane clipping and provides stable light quality, eliminating the need for constant adjustment. The NV4G operator interface has been designed for maximum flexibility and ease-of-use. Operators can adjust the clip parameters for trash, panel sizing and where to clip (combining defects or clipping the center of the defect), in order to optimize recovery, capacity and/or end product type.

We needed to better understand and get control of our processes. We felt that automating the grading process would help us determine the best products that we should be producing for our market.

Better data

Improving the quantity and quality of information from the production process was also a goal of the scanner upgrade, and the new NV4g scanning system provides production reporting including grade distribution, downtime and wood species processed. The system also allows for “virtual clipping,” using stored ribbon data, which gives the user the ability to test and change parameter settings before an actual production run in order to view the results and optimize clipping strategies based on market needs. All system parameters and clipping strategies can be customized at the touchscreen operator interface and saved to tables. System diagnostic information is also readily available to machine operators and maintenance personnel.

Second phase

Six months after the new greenend scanner was installed, the plant installed two new Ventek GSc2000 dry veneer grading systems at the outfeed of the full sheet dryers. Like the NV4g, the GSc2000 has a .060 in. scanning resolution. It also incorporates True Color vision technology, with industrial cameras and lighting to provide enhanced defect recognition through varying background color and changing light conditions.

“The GSc2000 provides better than 95% grading accuracy for the dry veneer,” says Chris Van Ackeren, formerly with Ventek and now USNR Account Manager, and the project manager for the Pollock mill install. “Because the system is automated, grading decisions are made with a higher degree of consistency than before.” “The scanners add objectivity that has helped us make better decisions,” echoes Richie LeBlanc.

The GSc2000 performs process data collection and interfaces to the plant’s remote management information system. The data that is generated enables the plant managers to track yields and make higher-level decisions affecting production throughput, product yields and profitability, with more confidence than was possible using the old, manual-intensive systems.

Implementation

The real challenge implementing the new systems came post start-up. “It took the operators some time to trust the data they were receiving,” said Richie, “but, once the team bought into the system it has proven to be very effective.” Training both on-site and at the supplier's Eugene, OR facility helped mill personnel gain confidence in the value of the data as well as learn to operate the new systems effectively.

Another support feature available, the system allows for USNR engineers to log in to the scanners remotely to provide assistance with diagnosing problems or making changes to adjust grades and clipping strategies.

Results

“I’m extremely satisfied with the overall results that we’re seeing from the data out of these systems,” said Richie LeBlanc. “The information that the scanners are providing, particularly on the dry end, is allowing us to make much more effective decisions in the day-today operation of our plant. We've been able to refine our product mix and improve recovery.” Hunt's management team has improved their ability to remain competitive, regardless of market conditions.