Insider
THE MAGAZINE FROM USNR | ISSUE 43
USNR ramps up its turn-key capacity USNR ADDS MID-SOUTH TWO THUMBS INCREASES UP FOR ENGINEERING, GRADING THG FOCUS ON WITH TURN-KEY
KIWI LUMBER BRINGS COMPARISON SHOPPING VISION TO SAWMILL –TRIMMER, WHY THG?EDGER
WORLD’S FASTEST CLOSING THE GAP BANDSAW LINEWITH STARTS, MILLTRAK 3D NEXT PHASE BEGINS
CONTENTS
Millwide Insider
SHIFTING GEARS, CREATING OPPORTUNITY USNR has seen some major changes over the past several years, acquiring Söderhamn Eriksson in 2015, Ventek in 2016 and now MidSouth Engineering in 2017. These are strategic, aimed at expanding the company’s presence in the European market, and enriching its capability in optimization for the veneer and plywood sector. This latest move spells a key shift in focus beyond singular markets and technologies. This change shifts gears for USNR as well as for Mid-South Engineering, and provides even better opportunities for our customers.
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MID-SOUTH ENGINEERING Mid-South Engineering, the leading engineering consulting company in the wood products industry in North America, was recently acquired by USNR. This new addition significantly expands USNR’s capacity to deliver turn-key projects to its customers.
KIWI LUMBER Kiwi Lumber was looking to improve its grade accuracy in the sawmill, to add value to its overall output. With over 110 vision scanning systems installed and operating world wide, USNR was a natural choice to partner in this endeavor. Kiwi is now keen to expand its product line.
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Tel.: 250.833.3028 subscriptions@usnr.com EDITOR Colleen Schonheiter colleen.schonheiter@usnr.com
USNR Woodland, WA: +1.360.225.8267 Mon. - Fri. 5:00 am - 5:00 pm PT 24/7 Service: +1.360.225.8267 www.usnr.com SÖDERHAMN ERIKSSON Söderhamn, SE: +46.270.746.00 Mon. - Fri. 07:30 - 16:30 CET www.se-saws.com
© 2018 USNR, LLC All rights reserved. POSTMASTER: Send address changes to 1981 Schurman Way, Woodland, WA 98674. Canada Post: Return Undeliverable Canadian Addresses to: USNR c/o Colleen Schonheiter, 3550 - 45th Street Southeast,
NORRA TIMBER This new bandsaw line, installed at a mill in northern Sweden, aims to be the fastest in the world. The first phases of this mill’s rejuvenation are complete, with the next phase – the final bandsaw in the line – to be completed in 2018.
SOUTHERN VENEER When Southern Veneer was ready to update its lathe line, it sourced USNR to handle the project. While major components came from a nearby closed plant, USNR implemented its next generation scanning and optimization platform, BlockLogix.
ISSUE 43 SUBSCRIPTIONS
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Salmon Arm, BC V1E 1X1
Mid-South Engineering
USNR ramps up its turn-key capacity NEW RELATIONSHIP; KEY WIN FOR INDUSTRY PROCESSORS USNR is pleased to announce that it has acquired North America’s foremost consulting and industrial engineering firm – Mid-South Engineering. This marks a significant step forward for both companies, reinforcing and building upon both USNR’s and Mid-South’s capabilities for the execution of large scale turn-key projects. Welcome to the future!
The expansion in our capabilities resulting from this acquisition will increase USNR’s capacity to offer large scale turnkey solutions.
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MID-SOUTH ENGINEERING – USNR RAMPS UP ITS TURN-KEY CAPACITY
For decades USNR has delivered turn-key projects to its customers around the world, but we have not had all of the internal resources we felt we needed to manage and run multiple turn-key projects on a large scale. That changed recently when USNR acquired Mid-South Engineering, the leading engineering consulting company in the wood products industry in North America. We’re taking the extensive experience, expertise, capabilities, and knowledge about the industry that both USNR and Mid-South possess, and establishing a combined force that can build a better result for our customers. This strategic move creates a step change for both USNR and Mid-South going forward. USNR and Mid-South have worked together on sawmill and plywood mill projects for many years, and both companies have benefited from this strong relationship. As separate entities we inevitably focused on optimizing our own segments of the project; together we can work to improve the execution of the entire customer project, reducing time, cost and risk , and delivering a superior integrated turn-key system.
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The players Mid-South is the largest full-service consulting engineering company in North America, established in 1969. It employs more than 100 multi-disciplined personnel, with a particular expertise around the building products industry. The company is based in Hot Springs, AR, and has offices near Raleigh, NC and Bangor, ME. Mid-South’s services fall into the categories of engineering, project development, project management, and construction. Its extensive list of services include mechanical
engineering and design, industrial project planning and development, electrical engineering, project management, production process development, civil engineering, construction, and structural engineering. The company boasts a who’s-who of clients in the lumber and panel industry, including Weyerhaeuser, West Fraser, Canadian Forest Products, International Paper, Georgia-Pacific, Martco, LouisianaPacific, Deltic Timber, Bowater Lumber, and a host more. Mid-South is also well versed in projects relating to biomass, pellets,
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Today the market is seeing a new trend, with a lot of our clients interested in turn-key projects. This will be a win for all parties.
lines, trim-sort-stack systems, dry kilns, and the optimization and control technologies to maximize the output and performance of that equipment. USNR is also known for its Söderhamn Eriksson debarker, sawlines, and high-speed edger systems, and its Coe- and Ventekbranded products used in the manufacture of plywood and other panel products.
Turn-key, or à la carte power generation, pulp and paper, and mining. Globally, USNR is the largest manufacturer of systems and services for the wood processing industries, with four manufacturing plants in the US, Canada, and Sweden, and more than a dozen regional engineering, service and sales offices across North America, and Europe. Employing around 1,000 individuals worldwide, USNR is best known for providing end-to-end solutions for sawmills and planer mills, including log lines, curve sawing gangs, edger
There is a trend in the industry toward more interest in turn-key capital projects. Wood processors are looking to concentrate more of their efforts on their business, their products, and markets. They want to take less of a hands-on approach to project execution and let experts take care of the details. Whether you’re looking for a turnkey partner, or you want to run your project using your own team, USNR is a strong option. If you want to build a complete new greenfield complex, expand your existing lines, or replace a single machine center,
USNR has all the elements required to take your project and run with it. Or you can pick and choose the products and services you want USNR and Mid-South to provide. It’s your choice.
Maintaining independence Although we expect that USNR and Mid-South will collaborate on many projects, Mid-South will remain an independent company and will continue to be available to serve its clients as an independent consultant. Mid-South will also continue to serve industry segments in which USNR has not traditionally been involved (biomass, aggregate, gypsum, power generation, etc.). By preserving Mid-South’s independence, wood processors will continue to have the option to work with other equipment manufacturers as they have in the past with full confidentiality. Similarly, USNR will continue to work with other engineering firms according to customer preference.
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MID-SOUTH ENGINEERING – USNR RAMPS UP ITS TURN-KEY CAPACITY
PROJECTS IN THE WORKS USNR and Mid-South are currently working together on a number of major projects as we have done in the past. While these projects are at various stages, we plan to begin streamlining the process to the degree appropriate for the stage of each project. Upcoming projects will afford even more opportunities to achieve synergy.
Mid-South connection
Arkansas
building layouts
A mill in Arkansas is updating its sawmill with a horizontal shape sawing system, bucking optimization, vision scanning on two edger lines, Multi-Track Fence and ElectraTong Lug Loader.
site work design
Another mill in Arkansas is making a major investment to install a new primary breakdown line, horizontal shape sawing line, two Counter-Flow dry kilns, 4200E electric planer, and Lineal High Grader (LHG).
electrical design for power distribution and plant lighting
Alabama This mill is installing a complete new planer mill including tilt hoist, stick collection, planer infeed, 4200E electric planer, and trim-sort-stack line. It is also investing in a sawmill line including optimization for log bucking and primary breakdown, horizontal shape sawing system, edger optimization, and green lumber handling line. Planning for this project allowed for the mill to keep up its operating pace throughout the project execution. Once the project is complete, the mill will produce over 3 times the current volume of lumber and replace the entire plant’s infrastructure, offices and production lines.
Mississippi A long-time customer is updating its curve saw gang to add canting and profiling. At the same time it is investing in a new trimmer-sorter line for its sawmill.
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On these projects, Mid-South is providing a range of services, including: preliminary equipment layouts bid specifications
design and engineering for the foundation, structural
steel, and walkways and platforms
Construction and site supervision on these projects is handled by USNR in some cases, and done by the customer in others.
Making contact There is no wrong way to make contact for either salesrelated information or engineering services. You can continue to make initial contact with either Mid-South or your USNR account manager. The contact you are most familiar with will take it from there. Engineering services will be quoted and delivered by Mid-South unless they are part of a turn-key project. For turn-key projects, USNR and Mid-South personnel will work together to develop a scope and an estimate, and to deliver the project. Adding Mid-South services to USNR’s portfolio brings a brand-new dimension to what is possible in turn-key solutions. Now you have a stronger choice for your next turn-key project.
USNR / MID-SOUTH TURN-KEY PROCESS Throughout a turn-key project, our team works with the owner to provide a balance of services to meet the customer’s needs for project planning, detailed engineering design, construction services, and implementation. Our goal is to provide the owner with an on-time, on-budget project, and to establish a relationship that leads to repeat business for the future.
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Project planning The engineering group helps customers take concepts and visions and turn them into preliminary project plans. These include preliminary designs and layouts, feasibility analysis, capital cost estimates, business analysis, preliminary project schedules, review of project execution methods, resource studies, mass balance calculations, and many other tasks that are a part of planning a project. A well-defined project scope and budget, and an agreed-upon schedule are the foundations for a successful project.
Engineering design Once an owner decides to fund a project, we provide project management and detailed engineering services. This involves developing the final dimensional controls for the process, developing equipment specifications, obtaining equipment pricing and installation cost, finalizing project budgets and project schedules, and setting up cost tracking reports. We develop all equipment layouts and interfaces, we layout and design equipment substructures and foundations, we perform electrical engineering for power distribution and control wiring, and we develop designs for the plant infrastructures (sitework, fire protection, roads, etc.), all with the thought of constructability in the construction phase, to facilitate the installation schedule.
Procurement As the design is finalized, our project managers begin finalizing contracts for subcontractors, and procuring the outsourced products and services. Our project managers understand that the project schedule is greatly influenced by procurement activities, so they work hard to insure that supplier information arrives in time to allow for proper engineering of infrastructure, and to allow for fabrication and delivery schedules that coordinate with installation and shut-down schedules.
Construction and installation During the construction period, we can provide on-site construction managers and/or construction coordinators. In this role, working with the owner we will coordinate contractors on-site, monitor the installation quality, and track the contractor progress to completion of the construction phase.
Start-up and commissioning As construction nears completion, we offer start-up assistance. These services can include pre-startup inspections, commissioning support, and post start-up evaluation of the equipment performance. In all phases, safety is our top priority.
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Kiwi Lumber
Making new grades SAWMILL VISION SCANNING IMPROVES OUTPUT, GRADE ACCURACY Kiwi Lumber was looking to improve its grade accuracy in the sawmill, to add value to its overall output. With over 110 vision scanning systems installed and operating worldwide, USNR was a natural choice to partner in this endeavor.
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A few years ago Kiwi Lumber knew it needed to update its aging edger optimization system. After careful evaluation it determined that the BioVision Edger solution from USNR would provide the return it was looking to achieve. On the heels of that success, the company came to USNR once again and selected its 4-sided Transverse High Grader to improve grade accuracy at the sawmill trimmer. With the synergy created by the edger and trimmer working in tandem to improve both the accuracy and value of its output, Kiwi is now keen to expand its grades and its product line.
Kiwi Lumber is a privately owned company comprised of three sawmill operations, all on the north island of New Zealand. It was started in 1996 with the purchase of a sawmill at Dannevirke, followed by mills at Putaruru and Masterton. All three mills process Radiata Pine, and Dannevirke and Putaruru cut pruned logs to manufacture appearance grade lumber which is marketed globally. Masterton’s output is structural and marketed primarily within New Zealand.
Hemco scanner that had been upgraded with a USNR optimization platform many years ago, and it was becoming a business risk. We knew it needed to be replaced. We thoroughly evaluated whether to go with just profile scanning or full vision scanning. When our evaluation was complete, we determined we would gain additional value with vision scanning. We knew that in some cases we would actually sacrifice conversion, but gain greater value in our output.”
Duncan Oakley, manager for the Masterton operation, said that the mill produces about 100,000 m3 each year, and added that the mill’s output has grown a lot recently. It runs a single shift – five 12-hour days. Besides the sawmill, it operates a continuous kiln as well as a conventional kiln, a planer mill, and a treatment plant.
The Edger BioVision project involved installing a new scanner frame outfitted with BioLuma 2900LVG sensors, and the advanced USNR grade optimization system. Duncan related that the mill achieved a good return from the project.
Edger BioVision The Masterton site has seen significant upgrades over the past few years, including vision scanning on its edger line in 2015, and followed this past year with a sawmill Transverse High Grader (THG) on its trimmer line. These projects brought together teams from Kiwi Lumber, USNR and Skookum Technology, USNR’s agent in the region. The Edger BioVision was installed before the Kiwi team took on the sawmill THG project.
Regarding the Edger BioVision upgrade, Duncan said, “The edger was operating with a dated V6
This new scanning technology opens up other opportunities for us to consider in terms of grades or products which we haven't produced before, but may be able to now.
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KIWI LUMBER – MAKING NEW GRADES
The installation team readies to put the new THG scanner frame in its place.
Sawmill THG The edger's been a good project for us, and its given us a good payback. It's still relatively early days, but we see the THG giving us a good payback too.
The next phase in improving the mill’s performance was to implement vision scanning at the sawmill trimmer. Duncan commented, “There was a slightly different motivation than we saw with improving the value of our product at the edger. For the trimmer, our target was more to increase our grade accuracy. We had been grading with manual graders, and with the lug speeds we wanted to run we weren’t getting the accuracy that we wanted from manual grading. In going to automated grading at the trimmer line, the goal was to increase our overall accuracy.” A component of the mill’s decision in choosing a vendor was to select a system that could integrate with
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the mill’s existing acoustic grader, for evaluating strength of the wood for structural products. Duncan related, “We did weigh other vendors besides USNR. We were happy with the USNR product in terms of what was presented, and we had a good established relationship with USNR with other upgrades we’ve done in recent years.” According to Duncan, another motivation for choosing the THG was to, “get the left hand talking to the right within the mill.” He said, “With vision scanning on the edger, it might be calling a piece a structural grade. But then when the piece got to the manual grader, he might override that decision. Having the two systems working in different parts of the mill, we can make sure that the decisions are in sync.” He
Having the two systems working in different parts of the mill, we can make sure that the decisions are in sync.
is unique, and looking back on the projects now, I think they went as well as they could have.”
The sawmill THG works in tandem with the Edger BioVision system at Kiwi. The THG has significantly improved the accuracy of the grade output.
explained further that they were seeing the situation where volume was sacrificed at the edger to gain value, but then they didn’t realize that value when the final grade decision was made on the piece. Duncan reports that now both Edger BioVision and THG systems are operating as anticipated. “Overall the edger ’s been a good project for us, and it’s given us a good payback. It’s still relatively early days, but we see the THG giving us a good payback too.” And he related that integration with the acoustic grader is also working as expected. There is a software upgrade that is due to be implemented on the edger, that will incorporate new algorithms for further improved grade accuracy. Duncan said that overall the vision scanning projects were very worthwhile investments. One key reason for determining the grade in the sawmill is the opportunity to accurately identify the true value of the piece at an earlier stage in the process. If you can sell it green, you may be able to recoup a higher value and not add
cost through drying and planing. If you believe it will make the SG8 grade, and go to the expense of drying and planing it, then discover it doesn’t make the grade, you’ve lost time, you’ve lost value and you’ve added cost.
Challenges and opportunities With any new technology but particularly true with automated grading software, development can be an ongoing process. Duncan described one example. “On the edger we had specific challenges around the knots that project through the wane, and with blonde knots. Additional development work was done by USNR to detect those knots.” USNR’s Stephen Wardrop, optimization technician, spent time working at site with the Kiwi team to further tune the systems for improved knot detection.
Describing the future outlook for the Masterton operation, given the new technologies that have been implemented, Duncan related, “This new scanning technology opens up other opportunities for us to consider in terms of grades or products which we haven’t produced before, but may be able to now. We can also refine our own grading rules to a degree, which we couldn’t do before.”
Ongoing evolution The vision scanning upgrades in the sawmill puts the Masterton operation in an enviable position to be able to capitalize on its improved output. In 2018 Duncan revealed the mill is upgrading its primary breakdown line with a new log infeed and log handling equipment from USNR. USNR’s experience in vision scanning includes over 110 installations of systems worldwide. A significant number is in the Australia / New Zealand region, with 20 systems now operating. With this much experience, USNR is a strong partner to consider when planning your next project.
He continued, “Both systems presented challenges, and I think that’s because of the complexity of tuning the systems to what we wanted to accomplish. Every site
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THG in Scandinavia
A top performer AUTOMATED GRADING IS PUT TO THE TEST IN SWEDEN In a recent technology study conducted by two independent Swedish industry groups, our Transverse High Grader (THG) was put to the test alongside other European automated grading systems. Among the 5 participating grading machines, THG performed exceptionally well in all aspects of grading for the Nordic market. These results confirmed that THG is a top performer among automated grading systems available on the global market today.
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With such positive results, we are confident that we have a very competitive automated grading system that meets all the needs of our market.
In July 2017, the Research Institute of Sweden (RISE), in collaboration with the Swedish Wood Technology Forum, conducted a study of automatic grading systems for lumber. The study involved five suppliers of technology for this purpose. Participating companies included RemaSawco, FinScan, USNR / Söderhamn Eriksson, Microtec and Lisker. The results of the project were presented in September at three locations in Sweden. Results were presented to approximately 100 wood processors at these venues. Setting goals A previous major study was conducted in 1996, and one significant goal for this recent study was to highlight the advances that technology has affected on the processes in this industry. Another goal was determining the capability of the grading systems to optimize the value of the lumber. The tests were designed for comparing the European standard for grading (EN-1611) to the Nordic Timber grading rules, to see how the outcome would be affected by using the different sets of rules. Eric Blomstrand, account manager with USNR / Söderhamn Eriksson, explained, “We do not have the same situation in Europe as in North America. In Europe it is up to the seller and the buyer to agree on the grade. The Nordic Timber grade rule book can be seen as a
recommendation. Often though, the rules are customized to fit customer demands. If you sell lumber according to the EN-1611 grade rules, then the grade has to correspond to that standard.”
Our system received high marks in comparison to what we observed with other systems in the survey.
Spruce and pine lumber were tested, both in side board (25 x 125 mm / 1" x 5") and center board or plank (47 x 148 mm / 1.8" x 6") dimensions. Appearance was the primary factor in determining value; lumber strength was not a consideration.
Put to the test USNR / Söderhamn Eriksson contributed its Transverse High Grader (THG) for the study. The tests that involved the THG were carried out at the company's facility in Söderhamn, Sweden, already set up to test customers’ lumber for defect recognition and classification.
THG TESTING RESULTS Material size
Sample size
Above grade (# pieces)
Above grade (%)
Below grade (# pieces)
Below grade (%)
Overtrim (# pieces)
Overtrim (%)
Undertrim (# pieces)
Undertrim (%)
25mm x 125 mm
154
3
1.9%
4
2.6%
0
0.0%
0
0.0%
47mm x 148mm
149
1
0.7%
5
3.4%
0
0.0%
3
2.0%
The number of pieces in each sample product size, and the THG's results. Knot
Unsound Knot
Dead Knot
Bark-ringed Knot
Wane
Dirt
Measurement Error
25mm x 125 mm
2
2
0
0
1
1
0
47mm x 148mm
0
5
1
1
1
0
1
Material size
The number and type of failures in detecting defects during the study.
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THG IN SCANDINAVIA – A TOP PERFORMER
The tests for this study evaluated each system for its performance in recognizing and classifying defects in 300 pieces of lumber. Then experienced manual graders took their turn to assess the pieces based on their established standards. Though specific results were not publicized outside the participant group, the study disclosed overall error rates for some systems exceeding 20%. With an error rate of less than 5%, the THG showed that it is a top tier performer (see tables, page 13).
our system received high marks in comparison to what we observed with other systems in the survey. We feel reassured that our THG excels in its performance for the Scandinavian market.” "With such positive results, we are confident that we have a very competitive automated grading system that meets all the needs of our market," he concluded. To learn more about our THG, scan the code or visit: https://www.usnr.com/ en/product/THGLM
Meeting objectives Eric Blomstrand commented, "We wanted to participate in the project for two reasons. First we were interested to learn how our THG compares with other systems in this field, and we also wanted the opportunity for our team in Sweden to learn more about board scanning and automated grading. While our teams based in North America have extensive experience in this area, this is technology to which our Swedish team has had more limited exposure.”
Excels in performance Eric continues, "The test results for the THG have been enlightening, as
Right: Eric Blomstrand presented the results of the THG's performance to wood processors at three venues in Sweden.
SPLITS / SHAKE
Below: Four faces of a Nordic pine board with shake highlighted in pink.
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KNOTS
Below: Four faces of a Nordic pine board with knots highlighted in green.
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THG IN SCANDINAVIA – A TOP PERFORMER
THE SCIENCE INSIDE THG With more than 110 vision scanning systems operating around the globe, and over 20 years of experience in grade scanning under our belt, USNR is an industry leader in this field.
DataFusion method DataFusion™ compares scan data from a variety of technologies to achieve the most accurate defect detection and classification. To collect this data, THG utilizes the advanced grade scanning sensor – BioLuma 2900LVG+, that integrates:
How DataFusion™ works: GrainMap images
XHG color vision images HD laser profile images
Grain angle data
Vision data
Image Processing / Defect Detection
Defect Assembly
Optimization
Geometric data
GrainMap™ grain
angle measurement
XHD color vision HD laser profiles LED illumination
Finding the pith Pith is key to locating and sizing knots hidden within a piece. THG models the pith to assist it in determining knot displacement, utilizing the following characteristics:
First the image from the end scanner is processed to find the grain pattern on the end of the board. This pattern is fit to concentric circles of a virtual log, to determine the starting pith position.
Next, once the 3 dimensional board model is assembled, and using the board's surface clues, knot projections are made to find a common point of intersection.
wane surface pith surface grain line patterns grain angles end grain knots An end grain scanner takes a visual snapshot of the end of a piece to model its grain pattern. This grain pattern is then fit into a virtual log to determine the starting pith position in the 3-dimensional board relative to its location within the modeled log. Once the board model is assembled, knot projections are developed to find a common point of intersection. The resulting information from these clues is integrated to determine the final pith model. Using multiple clues allows THG to track the pith even though it moves through the piece.
Finally, using multiple clues allows THG to track the pith even though it moves through the piece.
Armed with accurate defect data, THG’s decision capabilities let you determine proprietary grades for: cut-n-2, cut-n-3, cut-n-4 sophisticated wane rules knot sizes / classification shake separation
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Norra Timber
World’s fastest bandsaw line LINE IS NOW OPERATIONAL, NEXT PHASE IS ANNOUNCED This new bandsaw line, installed at a mill in northern Sweden, aims to be the fastest in the world. The first phases of this mill’s rejuvenation are complete, with the next phase – the final bandsaw in the line – to be completed in 2018.
It’s exciting to work toward achieving the fastest bandsaw line in the world, and to challenge the market with this unique solution.
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NORRA TIMBER – WORLD’S FASTEST BANDSAW LINE
A view from the ChipCanter 2500 to the Logmaster bandsaw
Northern Forest Owners’ (Norra Timber) sawmill at Sävar, in North Sweden, recently announced it is ready to complete the transformation of its saw line. The primary breakdown process features bandsawing technology, and the secondary process includes a new edger line, all from USNR / Söderhamn Eriksson. To date, two twin Logmaster HPS bandsaws are now operational, with the third Logmaster unit to be implemented in 2018. This bandsaw line aims to be the fastest in the world when it is complete.
750E rotary log turner
ChipCanter 2500 Cant LogPos S4 turner conveyor
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ChipCanter 2500
Logmaster HPS bandsaw Cant turner
Skid bar conveyor
High speed and yield “If the third bandsaw is running next year, we will have achieved one heavy duty saw line,“ says Fredrik Samuelsson, production manager at Norra Timber ’s Sävar location. Samuelsson explained that the target of 155 m/min (500 ft/min) feed speed is expected to be achieved after the next stage of the expansion is completed. But precision cutting is already setting new standards at the mill. The earlier installation of two Logmaster HPS bandsaw units is now up and running, and the mill estimates double-digit volume increases due to improved cutting accuracy and thinner kerf sawing, as opposed to circular saw blades. The Sävar saw line processes a wide range of timber in all dimensions, from 120 mm to 400 mm (5 to 16”), and log weight can vary from approximately 70 kg to one tonne. The average speed of the old line was 65 m/min (215 ft/min), so the target of 155 m/min for the new system is a lofty goal. Besides increasing the line speed, a far thinner kerf is also in the works. The goal to halve the already thin saw cuts of only 3 mm to 1.5 mm is a much tougher challenge. “I have high hopes that we get down to 2 mm cuts in our new line, and then we will have halved the kerfs compared to circular saw lines, which rarely come under 4 mm,” says Stig Grundberg, sawmill manager at Sävar and technical director for Northern Forest Owners.
Cants are turned in preparation for processing by the second Logmaster bandsaw unit.
When fully implemented, the new bandsaw line is targeted to achieve high speed ribbon cutting, in the range of 155 m/min. The line will include: 750E Rotary log turner LogPos S4 log infeed
If the third bandsaw is running next year, we will have achieved one heavy duty saw line.
Two ChipCanter 2500 reducing units Three Logmaster HPS bandsaws
Existing bandsaw (to be replaced with Logmaster HPS)
Logmaster HPS bandsaw Sideboard separator
Rotary cant turner
Sideboard separator
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NORRA TIMBER – WORLD’S FASTEST BANDSAW LINE
We have enjoyed a good relationship of cooperation with USNR / Söderhamn Eriksson.
Saw blade monitoring: improves accuracy, safety The new Logmaster HPS runs continuously at a band speed of 100 m/sec. (328 ft/sec.). To avoid blade rupture, it is of utmost importance to have a reliable and exact monitoring system. This is where the newly developed BMS - Bandsaw Monitoring System - comes in handy. Like USNR / Söderhamn Eriksson’s renowned system for blade monitoring, Vision Tilt, the BMS system monitors the blade’s position on the wheel. While Vision Tilt uses a camera, the BMS system uses inductive sensors that monitor the blade, and an actuator that tilts the upper band wheel’s vertical position. The main advantage to using inductive technology is the capability to detect cracks in the blade, even very small ones. Apart from safety risk and damage to equipment, blade ruptures create downtime. One customer indicated that the BMS investment has a very short pay-back time, as well as 100% crack detection (zero blade ruptures). He said that thanks to increased up-time in the saw line, the mill’s production has risen on average by an impressive 1.9 cubic meters (800 board feet) per hour. The BMS’ sensors are mounted in a protective housing on the return side of the saw blade. The BMS’ detection capability is not reduced by sawdust build-up or particles in the air. BMS actively corrects the saw band’s position on the band wheel, which not only minimizes wear but also improves sawing accuracy.
Cants enter the Logmaster HPS bandsaw.
Looking to the future
“Norra Timber is a very independent company. It includes all the elements of wood production and processing right through to the final product,” concludes Fredrik Samuelsson. “Next year there will be even further modernization at the Sävar plant.” “We have enjoyed a good relationship of cooperation with USNR / Söderhamn Eriksson. It’s exciting to work toward achieving the fastest bandsaw line in the world, and to challenge the market with this unique solution,” says Stig Grundberg.
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To view a video of the line in action, scan the QR code or go to: https://www.usnr.com/en/product/ logmasterhps/videos
Portions of this article were used with permission of HolzKurier magazine.
Southern Veneer
Recovery ramps up YIELDS 4% MORE RECOVERY, 10-15% MORE PRODUCTION When Southern Veneer was ready to update its existing lathe, it acquired major components from a nearby closed plant, and proceeded to source a vendor for the project. The goal was to increase productivity and veneer quality, improve fiber recovery, and at the same time decrease downtime and maintenance costs. Taking on this project, USNR also realized the opportunity to introduce its next generation scanning and optimization system – BlockLogix, based on the BlockPLUS system.
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SOUTHERN VENEER – RECOVERY RAMPS UP
We’re averaging 4% increase in recovery. We've been able to decrease labor costs by at least a shift each week and still achieve 10-15% more production volume.
A retrofit Coe Model 1380 core drive holds a block against the lathe knife for peeling, while a new pendulum readies another block for its turn.
Southern Veneer is situated at Fitzgerald, Georgia, in the heart of Southern Yellow Pine country. The major production focus for the plant is veneer that is primarily marketed to producers of LVL panels. The operation includes a log yard, lathe and green end line, vintage Coe dryers, lay-up line, 10-bin Coe dry stacker, press line, and a saw line. Capacity is in the range of 200 million board feet annually. The operation is privately owned by Kendall and Tammy Adams, and the plant is managed by Rick Payne. The Southern Veneer team is a tight one, having worked together for many years and enduring together through the up and down cycles this industry is famous for. Input for the article came from the following team members who each had a hand in the success of the project, including Robert Clark, special projects coordinator; Mike Edwards, maintenance and electrical supervisor; Barry Donnelly, green end superintendent; Amy Tharp, CFO; and Juan Medellin, sales and production manager.
Detailing the plan The 20-year-old lathe required significant modification to achieve the level of production and reliability the team was looking to realize. Southern Veneer also wanted to incorporate scanning and optimization in the mix, to improve recovery. They determined that USNR offered the best package to bring the lathe system up to the performance standard they required. The team related, “USNR offered the best complete package, as well as service and support.” And having dealt with USNR (Coe) in the past, the Southern Veneer team knew they could count on USNR to be there for future support. The project was completed in two phases. Along with the installation of the newly-acquired Coe Model 790 XY charger and Coe Model 1380 core drive, the line was updated with a new charger pendulum, new hydraulic power unit to operate the XY charger and infeed step feeder, BlockPLUS (XY scanning and optimization system) and ControlLogix PLC motion control for all of the lathe mechanical functions. The first phase of the project went
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off without a hitch, and quickly got the plant up and running. The second phase would require programming changes to the BlockPLUS system to transition it from VME to the ControlLogix PLC platform. The next generation scanning and optimization system is called BlockLogix™. The charger's first scanning system was started up using a temporary VME controller while the new ControlLogix PLC software code was in development back at USNR. The team knew going into the project that the second phase would require more time because of this effort. They explained, “We knew the installation of the second phase was going to take time. We also ran extra production leading up to the second phase so we didn’t lose any production during the changeover.”
Executing the second phase The second phase involved designing the PLC controls system to transition from the VME controller to the ControlLogix platform. Tim Dezellem, USNR controls technician, master-minded this second phase. He explained, “After the first phase
USNR offered the best complete package, as well as service and support.
The lathe peels a block, while another is picked up by the pendulum, and a third rests on the pre-centering vee, waiting it's turn to be scanned.
was completed, everything except the XY scanning was controlled via the ControlLogix PLC. Phase two eliminated the requirement for the VME processor. Positioning of the XY spindles and the block rotation are accomplished through the PLC, while the optimization is done through a Dell server PC.” He went on to say that this was USNR’s first full PLC motion controlled lathe deck, and was a significant project that required input and coordination between multiple USNR teams to integrate the redesigned system.
The BlockLogix system Once a block is loaded on the charger's pre-centering vee, each end is sized to determine the best geometric spin axis, and the XY spindles engage the block ends accordingly. As the spindles raise and rotate the block it is scanned every 0.05 inches along the length of the block and nominally every 1 degree of rotation. The optimizer receives the scan data and analyzes a multitude of possible lathe peeling solutions before generating the best solution. This solution is passed to
the PLC to reset the splindles' axes before the pendulum picks up the block, to achieve maximum fiber value. Beyond maximizing veneer recovery and value, a secondary outcome is minimizing lost time in the block peeling cycle, thus improving production. The optimizer calculates the volume of veneer that can be recovered from the block. When the peel is completed the PLC communicates the point at which the peel stopped, and that information is used to generate management reports that display the optimized solution vs the actual volume of veneer recovered from each block.
We ran extra production leading up to the second phase so we didn't lose any production during the changeover.
Adding up results The team saw impressive results after the project wrapped up. They said, “It’s given us more recovery, saved on labor and maintenance costs, saved material costs through increased recovery, and we’ve seen a significant decrease in downtime.” They went on to quantify some of their comments. “We’re averaging 4% increase in recovery, and between 10 and 15% increase in
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SOUTHERN VENEER – RECOVERY RAMPS UP production. We’ve been able to decrease labor costs by at least a shift each week and still achieve the 10-15% more production volume. Weekly maintenance cost has been dramatically reduced. This project has exceeded our expectations.” Southern Veneer was very appreciative of the team effort displayed by everyone involved. “We helped USNR’s team on the install, and they stayed for about a week afterwards to train us on how to operate and maintain the system.” Besides those who offered input for the article, the Southern Veneer team also provided rave reviews for these team members: Dennis Crager, Jose Trejo and Juan Carlos Trejo (lathe operators), and Jeff King Contractors. Now that the project is behind them and the lathe line is humming along, the team looks to the future with anticipation. They’ve enjoyed several years of steady markets, and are hoping to expand their product mix in the near future. This project is helping Southern Veneer to achieve its goals.
Right: The user interface is user-configurable to view information in a variety of ways. Data displays the optimizer's solution for each block including the block's geometric measurements, volume of veneer, block and charger positioning offsets, etc.
Left and above: A variety of screens, views and information is available depending on user security level and preference.
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BlockLogix: Evolution in lathe optimization More than 10 years ago Coe introduced the first high density (100,000+ data points) XY charger scanning and optimization system, BlockPLUS, and it has been providing good returns for many veneer lathe customers. Since then USNR introduced its next generation system based on BlockPLUS. It is appropriately renamed BlockLogix™ in recognition of its transition to the Allen-Bradley ControlLogix motion control platform. There are significant changes to this system that make it a better package for our customers. The BlockLogix system features: Fast, efficient processing The highest fiber recovery Simple to maintain, troubleshoot Few electronic components The BlockPLUS system was designed to work with the VME control platform, with the controller software embedded within the optimization architecture. While this configuration is fully capable of generating highly accurate peeling solutions, it is more cumbersome to program and troubleshoot. BlockLogix uses ControlLogix, an industry standard in many regions. With BlockLogix, the PLC control software is separate from the optimization architecture, making it easy to adjust motion control functionality. And troubleshooting can usually be performed by your plant's technical personnel. BlockLogix optimization is based on the Windows platform, another industry standard. The streamlined code makes it easy to adjust optimization parameters. And together with new, powerful computer hardware, BlockLogix can process more data faster, allowing an increased number of computations before generating a solution.
No more pac chassis! Another development with BlockLogix is ethernet-based scan heads. With these sensors, the pac chassis – the computer that was required to collect the scan data and transmit it to the optimizer and PLC controller, is no longer necessary. The user interface is also designed to align with USNR's standard user interface for optimization in solid wood applications. This evolving system is one more example of USNR’s continuing development and support for its range of panel products. To learn how BlockLogix can benefit your operation, please contact us at www.usnr.com.
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NEW PROJECTS Balcas Timber – Stick-NStacker Upgrade Balcas Timber is updating its stacker line at its sawmill at Enniskillen, Northern Ireland. The order features USNR’s Stick-N-Stacker with electric actuation, providing high-speed, uniform packages with near perfect stick alignment. This latest stacker design includes a variety of nowstandard enhancements, and can operate at speeds of up to 20 cycles per minute. The supply will also provide a lumber step feeder to efficiently singulate boards feeding the new radius back unscrambler. The stacker is designed to accommodate package sizes of 1200mm (48”) wide x 1400mm (55”) high x 6.17m (20’-3”) long stickered. Balcas is one of Britain’s and Ireland’s largest sawmills, supplying construction timber, fencing and landscaping products, and pallet and packaging material.
Continuous Tilt Hoist at Carrier Lumber
Boise Cascade – Core drive Boise Cascade at Oakdale, LA is investing in a new core drive for its No. 1 Lathe. This upgrade will improve the recover y and quality of wood fiber during its peeling process, and allow it to peel down to small diameter cores. The new core drive is designed to minimize deflection of the block in the lathe as it is peeled to small diameters, improving recover y. This equipment will permit peeling of incoming blocks from 6” to 36” in diameter.
Claude Howard Lumber – Counter-Flow Dry Kiln Claude Howard Lumber is investing in a new Counter-Flow Dr y Kiln for its operation at Statesboro, GA, the second such kiln for this mill. This order is unique in that it includes a Green Fuel Burner in combination with a natural gas burner. The two fuel systems will operate independently.
This kiln will be 210’ long. The Kiln Boss control system will manage the dr ying process. USNR also made several upgrades to insure a long life, including improved panel materials, unique rail and concrete design, and upgraded pusher, tram, and fan components. This design delivers continuous non-stop production, enabling you to increase kiln production by up to 50%. USNR pioneered the design, and installed its first Counter-Flow Kiln in 2005.
Roseburg Forest Products – Major Investment Roseburg Forest Products of Springfield, Oregon, is expanding its Laminated Veneer Lumber (LVL)
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business with a major investment in a new plant in South Carolina. The complex is planned for Chester, South Carolina and will manufacture LVL from Southern Yellow Pine. This investment is expected to make Roseburg the largest US manufacturer of engineered wood products ser ving independent distributors. USNR will supply a significant amount of equipment including billet handling, sor ting & storage, stacking, packaging and outfeed lines, gang rip saw, sealing & spray lines, reman chop saw line, horizontal bandsaws. PLC controls will be supplied, as well as WinTally™ sor ter management, ticketing system, and grade mark reader.
This new plant will create 148 fulltime jobs. Construction is targeted to commence in early 2018, with star t-up planned for mid2019. USNR is proud to be a par tner in this major project.
With over 120 units sold globally since its launch in 2010, this fence is an excellent choice for high-speed optimized applications offering infinite resolution, and guaranteed at 0.125” (2.5 mm) accuracy at 200 lpm.
Spearfish Forest Products – Continuous Tilt Hoist
Wespine Industries – Edger BioVision
Spearfish Forest Products at Spearfish, South Dakota is replacing an existing beam-style hoist with a new Continuous Tilt Hoist from USNR. The order includes package infeed, continuous hoist, Stick Collection system, and MillTrakcontrolled back log complete with variable controlled transfers.
Edger BioVision is the latest investment for Wespine Industries at Dardanup, Australia. The company’s existing Edger optimization system will be upgraded to add defect recognition to its green mill process. Edger grade extraction provides value through re-manufacture or rip based on the ultimate grade of the wood.
This investment will increase productivity and smooth the flow of material to the planer.
The existing transverse scanner frame is already fitted with BioLuma 2900L laser profile sensors. Those sensors will be replaced with BioLuma 2900LVGs, adding vision and grain angle measurement to its scan data. As well, an end scanner will identify the pith location relative to the board’s origins within the parent log.
Tembec – Multi-Track Fence The Tembec mill at Kapuskasing, ON is investing in a new Multi-Track Fence for its sawmill. The new fence will improve the speed and accuracy of the mill’s sawmill trimming process. The Multi-Track Fence is designed at a lug rate of 200 lpm for this installation. The mill processes stud length material from spruce, pine and fir.
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PROFILE Will Brennan: Account Manager based at Salmon Arm, BC Will Brennan is a recent new face to the USNR team, with past experience in biomass and other wood processing sectors. After working for years in industrial manufacturing, he took a program in Mechanical Engineering Technology at BC Institute of Technology. Will’s customers are located throughout Canada’s 4 western provinces. He commented, “I appreciate that my western Canadian region has diverse
UPCOMING EVENTS
customers with unique needs to keep me on my feet, and that there are so many people here with a wealth of experience and expertise to draw upon.” He continued, “I knew several of the innovative brands that are part of the USNR family today. Not only that machiner y, but the histor y and people here are what drew me to USNR.” When he has time away from work, Will enjoys taking his two young boys to hockey, Tae-Kwon-Do, and other activities, and travelling with his wife.
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11 FEBRUARY SLMA Regional
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