Insider
THE MAGAZINE FROM USNR | ISSUE 44
Automated log line, designed in Sweden USNR ADVANCES THE TWO TIMBER THUMBSBUILDING UP FOR MASS GRADING WITH THG REVOLUTION
VIIRATSI: SWEDISH COMPARISON SHOPPING MACHINE DESIGN ADDS – WHY THG? USNR OPTIMIZATION
MAJOR HARDWOOD CLOSING GAP WITH VENEERTHE PRODUCER MILLTRAK SELECTS3D USNR DRYER
CONTENTS
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INGENUITY TAKES MANY FORMS
ISSUE 44
This issue features stories about ingenuity. The vision of companies that are getting into the North American CLT market early shows their foresight. Combining USNR’s legendary optimization with our European machine design proves the skill and determination to broaden our technology horizons. Strategic ingenuity went into expanding our service organization, to bring customers a small company feel with big company backing. And the efficient design of our veneer driers is keeping a long-term customer in good standing in a competitive marketplace.
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MASS TIMBER BUILDING REVOLUTION USNR has been building presses for a very long time, and recently set our sights on the hot CLT market. We’ve had success with our design, and are currently manufacturing a new press for Katerra, along with a spate of ancillary equipment for their new greenfield manufacturing operation. Read more about this building paradigm.
VIIRATSI SAWMILL This sawmill in Estonia recently underwent a major improvement with a new primary log line, designed by USNR in Sweden. Key to the design is the SuperSaver concept. At the same time it implemented our Catech edger system. Both lines utilize USNR scanning and optimization, and both started up with ease!
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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
© 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, Salmon Arm, BC V1E 1X1
USNR SERVICE EXPANSION Our service organization is expanding to bring you a more localized support experience. We’ve developed regional service teams that will provide more rapid response times, and help keep costs lower, and faces familiar to you. Check it out!
BROWDER VENEER North America’s highest producing hardwood veneer operation came to USNR for a new veneer dryer to match the expanded capacity of its peeling process. Its solution is doing exactly what it envisioned, and helping it face stiff market forces with a positive outlook.
SUBSCRIPTIONS
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Mass Timber
Building revolution ADVANCING THE MASS TIMBER BUILDING PARADIGM After a long history making presses, USNR entered the CLT press business in 2015. Since that foray into this emerging market in North America, the growth in interest has taken off at a break-neck pace. Thanks to stakeholders, the progression has been orderly while the enthusiasm remains fervent. Getting into this business isn’t straightforward. There are rules and regulations that need to be met ahead of gluing the first commercial panel. Read on to learn about the process, and the experience of others who have taken the plunge.
WSU has a long history of working with wood, and testing and evaluating the manufacturing processes. With the Katerra project we are determining how their manufacturing process will go together.
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MASS TIMBER – BUILDING REVOLUTION
While the market for mass timber, including cross laminated timber (CLT), is still very new in North America, it is growing rapidly. Its growth here is bolstered by the experience gained from other regions like Europe, where this technology and building method was adopted over 20 years ago, and is expected to triple its 2016 production volumes by 2020. That is a testament to just how strongly this new construction medium is taking hold. It’s bringing not just a new component to the mix, but a whole new paradigm for building construction.
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USNR’s progression to CLT Though USNR’s design for its CLT press is quite new, its roots stem from its vast experience with the Washington Iron Works and MannRussell lines. For many decades these brands operated under the Coe name (now USNR), producing equipment for engineered wood products like LVL and OSB panels, and beam and finger-joint stock. USNR’s CLT press design is a natural extension of that technology. In addition to the press, USNR provides complete lay-up and material handling lines, as well as radio-frequency generators for press applications. USNR’s systems produce dimensional lumber, plywood and panels, finger-jointed components and engineered wood products world wide. In 2015 USNR designed, manufactured and installed its first CLT press for Riddle Laminators at Riddle, Oregon. Owned and operated by D.R. Johnson Lumber, the plant was the first in North America that was certified to manufacture CLT panels under a new standard approved by the American National Standards Institute (ANSI), and its products were tested and certified by the Engineered Wood Association (APA). The standard for certification developed by the APA and ANSI provides dimensions and tolerances, performance requirements, testing methods, quality assurance, and trademarking. Detailed information about the standards (ANSI/APA PRG 320) can be obtained at www.apawood.org. Certification paved the way for the company to market its 3-lam, 5-lam, and 7-lam CLT panels to the U.S. wood construction market. At initial installation, the maximum panel size produced was 10’ x 24’ in 3, 5, or 7 layers. Since then the plant has installed three 6’ extensions to the press. At WSU’s research and testing lab, a billet is being assembled for the press.
USNR offers both pneumatic and hydraulic presses in a variety of sizes. In addition to the vertical forces placed on the panels, these
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MASS TIMBER – BUILDING REVOLUTION
We bridge several technology gaps, from the processing side to the implementation side.
Press animation:
https://www.usnr.com/en/ product/cltpress/videos
presses also apply side and end forces. USNR’s design is unique in that its press is modular, with the capability to be easily expanded to manufacture longer panels. After its successful installation of the CLT press design at Riddle, USNR has fielded many inquiries and is in the process of delivering a new CLT press line near Spokane, WA for Katerra. In addition to the press, USNR will also supply a complete planer mill and all the material handling equipment to complement the press line for the Katerra complex. Katerra Inc. is a forward-thinking company headquartered in Menlo Park, Calif. with global operations, including U.S. facilities in Arizona,
California, Georgia and Washington. As an end-to-end construction and technology services company, Katerra applies systems approaches to remove unnecessary time and costs from building development, design, and construction. That concept led it to complement its existing business with CLT panel manufacture.
Oregon State University The Department of Wood Science and Engineering at Oregon State University (OSU) provided research and testing in conjunction with D.R. Johnson Lumber for the CLT press they purchased from USNR. This work subsequently led to its certification. Since then, the OSU College of Forestry, OSU College of Engineering, and University of Oregon School of Architecture and Allied Arts collaboratively opened the TallWood Design Institute to further the research and education, and to promote CLT as it relates to tall wood building design. USNR is taking an active role in the promotion of CLT and mass timber building initiatives. Account Manager Allan Czinger, an OSU alumnus, is on the Educational Advisory Board working to develop a new degree focus on renewable resources, to be called Advanced Manufacturing. Allan says, “ The graduates of this new program will be the people our customers will want to hire, with a degree that combines wood science and business management.”
Washington State University
The side view of the loaded pneumatic press at WSU.
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About a year ago Katerra approached a group at Washington State University (WSU) to undertake research and testing for a new CLT panel processing plant the company planned for Spokane Valley, Washington state. USNR Account Manager Eric Ortquist, an alumnus of WSU, has been involved with the Katerra project and WSU’s research. He explained, “Katerra ordered a press with ten 6’ sections for production (60’), and an additional 6’ section for research and
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MASS TIMBER – BUILDING REVOLUTION development. The 6’ R&D section was shipped to WSU for the testing. That section will produce a 6’ x 12’ panel. Katerra also ordered a layup table (rollcase for laying up the material) and then a glue system that were delivered to WSU, because they started out gluing them by hand.” Associate Research Professor at WSU, Karl Englund heads up the research and testing team. He explained the purpose of the WSU involvement, “It is based upon utilizing the expertise of our group to facilitate the production of CLT through Katerra. WSU has a long history of working with wood, and testing and evaluating the manufacturing processes. With the Katerra project we are determining how their manufacturing process will go together.” He went on to explain that WSU works with the resins, glues, species, and all facets of the materials, to understand how they behave collectively. Then they look at how the panels are fastened together, and how they go together in a building’s design. “We bridge several technology gaps, from the processing side to the implementation side.” One of the goals of the testing on behalf of Katerra, is to achieve certification for both the process and the panel products. Karl explained, “A lot of these initial processing parameters need to be ascertained before Katerra gets its production plant up and running. We’re doing a lot of that work, as well as qualification for the panels. Our goal is to get further down that pathway
Our goal is to get further down that pathway to certification before the press is commissioned.
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USNR’s Sam Pope and his wife Carla (left and center) accept the Innovator of the Year award from EWTA Managing Director Terry Kerwood.
to certification before the press is commissioned. Understandably, Katerra’s goal is to start selling product as soon as possible. The work we are doing is laying the groundwork for that to happen.” Karl went on to explain, “Some of the parameters that are included in the panel testing is how well the adhesive sticks, and then how the panels perform within a building.” He said that other tests include how the panels perform with a wind load, seismic load, or just a dead load. Karl explained his role at WSU, and how it relates to the Katerra project. “A lot of my work has been focused on industrial outreach. I work with industries in the field of wood science for forest products. My strength is on the processing and material science, and I’ve been heading up that work. We also have faculty that are working on the larger scale systems like testing for the building and structural design, as well as meeting building codes.” As the Katerra project progresses, USNR is not only working on the designs and manufacturing of the equipment for this new facility, but is also collaborating with all parties to ensure a successful outcome.
Innovation award In 2017 USNR received the Innovation of the Year Award from EWTA (APA affiliate). The award recognizes a company providing a new technology, product or service that has been shown to reduce production costs, increase productivity, improve product quality, or in some other way provide a bottom line benefit to APA members. USNR’s new modular press for the manufacture of cross laminated timber panels features the use of compressed air instead of hydraulics, which sets it apart from other CLT presses. Once the CLT panel is fed into the press, a set of pneumatic cylinders applies pressure from the sides to ensure minimal gaps between core materials within a given layer. Meanwhile, a set of channels carrying eight, large-diameter pneumatic hoses is lowered to rest atop the CLT panel. Once the panel is configured correctly, the hoses are brought to pressure. The method is a more costeffective and environmentally friendly one than the hydraulic alternative.
Viiratsi Sawmill
Flexiblity, advanced automation NORDWOOD’S VIIRATSI SAWMILL TAKES MERRY-GO-ROUND SYSTEM TO A HIGHER LEVEL This is the first saw line featuring Swedish mechanical design paired with USNR scanning and optimization technology. The result is exactly what was needed for this processor, and proves the flexibility of the solution.
The main objective of the investment was to offer forest owners the opportunity to supply all the possible assortment of logs to one factory.
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VIIRATSI SAWMILL — CLASSIC SETUP, MODERN STANDARDS
Viiratsi Saeveski AS is one of three sawmills in the Nordwood group in Estonia. In 2016 they started discussions with USNR about a new saw line for large diameter logs to match their existing small log line. Availability of raw materials was a key factor. Competition in the market for small logs had increased significantly in Estonia, making it hard to grow by volume. The sawing capacity in Estonia is also bigger than the availability of raw material. Therefore it was necessary to extend the raw material base to keep the volume of sawn material. Nordwood’s lumber is used in a wide variety of applications such as construction works, furniture, packaging and wood industry. Hence, Viiratsi needed a flexible solution which could manage a broad variety of saw patterns. The solution to this
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equation spells out the SuperSaver merry-go-round line. The merry-go-round sawline, together with an optimized edger line, is a common solution in many regions, and in Scandinavia it is closely associated with the Söderhamn Eriksson brand. To learn more about the concept, see the fact box at the end of this article. We asked Tõnu Ehrpais, the mill manager, why Viiratsi Saeveski chose to go for the SuperSaver solution. “ The decision was based on an economic estimate. With bigger logs, the investment principle
Based on our raw material, optimum saw patterns plus the maximum possible curve sawing recovery is needed to achieve our goals.
was to get a maximum monetary yield out of the raw material. Based on our raw material, optimum saw patterns plus the maximum possible curve sawing recovery is needed to achieve our goals.” Mr. Ehrpais underlined the competition for raw material and the role of the suppliers, “The main
objective of the investment was to offer forest owners the opportunity to supply all the possible assortment of logs to one factory. Before this investment, the Viiratsi Sawmill was a small log sawmill. Upon completion of the new line, we can handle logs with diameters from 8 to 50 cm at the small ends, and with lengths of 3-6 meters.” The Viiratsi sawline is a complete USNR line from the Cambio 800 debarker to the resaw and the Catech edger line. The Viiratsi is also the first saw line produced in Sweden with USNR optimization. A great effort was put into adapting the USNR optimization software to the new machinery. This work was done through a tight cooperation between Swedish technicians and the USNR optimization team in Parksville, BC. The advanced optimization, together with sweep sawing technology and the Catech edger optimizer, guarantee a high recovery level.
Catech Edgers Catech edgers have long been the top-of-the-line trademark for high speed softwood edging. Scanning and measurement technologies have evolved throughout the years, and now USNR’s BioLuma technology has been implemented. The standard scanner heads in Catech systems are now BioLuma 2900L. The scanners feature laser scanning at a resolution of 0.3” (8 mm) at a scan rate of 2500 Hz over the full length of the board. As an option, the system can be fitted with vision scanning for full value optimization. Recently, the first two Catech systems with BioLuma technology have been installed, one in Fiskarheden Sawmill, Sweden, and one in Viiratsi.
Why Catech? Margo Jaska, technical manager at AS Viiratsi Saeveski explains why they chose the Catech edger for their new sawline, “The edger was chosen mainly because of the capacity – with a peak capacity of up to 70 boards per minute, and an average speed of
Pictured above: Catech Edger utilizing USNR optimization with BioLuma sensors.
55 boards per minute. Other vendors in Europe did not have an edger with such capacity.” BioLuma 2900L geometric profile scanners with USNR’s optimization package were chosen based on the precision and reliability that are proven out over many installations.
Smooth installation
With a peak capacity of up to 70 boards per minute, other vendors in Europe did not have an edger with such capacity.
The performance of the machinery once it’s up and running, is only one of many parameters to consider in the process of buying new equipment. A smooth installation and commissioning process is important
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VIIRATSI SAWMILL — CLASSIC SETUP, MODERN STANDARDS as well. When we asked Mr. Jaska about the Catech installation process his answer was very concise, “The installation process went unnoticed. That is a good sign of assembly quality and professionalism of the startup/installation crew.”
are steadily rising and pushing manufacturers to invest in equipment that provides better financial return, especially the hardware and software scanning systems. Companies that have not invested or are not going to do this in the near future, have already finished or stopped production. A steady growth of wages, 5% per year, and low interest rates will make all investments attractive that reduce the number of employees per unit of production.”
Mr. Tõnu Ehrpais also commented on his general view of the market in Estonia and the Baltic countries, “The development of the sawing industry at the local region is ensured with the availability of raw materials, and with fast development of post processing. For example, in Estonia, since 2012, the import of sawn timber has been higher than the export. In the near future, the production capacity of laminated timber products will grow even further, and therefore the use of lumber in post processing will likely increase. The installed sawing capacities will exceed the amount of raw material usage. Log prices
Upon completion of the new line, we can handle logs with diameters from 8-50 cm at the small ends, and lengths of 3-6 meters.
To view a video of the line in action, scan the QR code, or go to: https://www.usnr.com/en/product/SuperSaverSM/videos
SUPERSAVER CONCEPT SuperSaver is USNR’s versatile concept for merry-go-round saw lines. The common denominator in all SuperSaver configurations is the compact layout, high recovery and high capital utilization.
Debarked logs enter the saw line’s scanner and the optimum saw pattern for each log is determined. The log is rotated into its optimized sawing position and fed into the canter. The cant is then fed on into the quad bandsaw where two or four sideboards are sawn off. The board separator separates the boards from the cant and sends them off to the
The Viiratsi line is equipped with a quad resaw for extra high output; this means that all patterns can be sawn with just two passes through the line.
Q re u a sa d w ba
B s e oa r pa d ra to r
er nt Ca
Q ba u a nd d sa w
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The core concept is the quad bandmill, through which the logs pass up to four times depending on log size and machine configuration.
edger. The cant is rotated 90 degrees before returning for the next pass.
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To green sorting
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Catech edger
Technical Service Expansion
Focus on customer satisfaction SMALL COMPANY RELATIONSHIPS, BIG COMPANY BACKING At USNR, supporting our customers is a big deal. We recognize that wood processors need a strong level of service from their vendors, and this is an important consideration when choosing who to do business with. USNR has grown rapidly over the years. We want to ensure customers still receive the personalized support that we developed as a smaller company. To this end we’ve developed regional service teams in North America that our customers in those regions will come to know well. With regional service teams we believe we will be able to provide customers faster response time, and allow us to maintain reasonable service rates, while putting known faces in your plant to assist you with scheduled, as well as critical service support. Our goal is to have USNR be your first choice for capital investments and aftermarket support by providing a level of service that is the benchmark in our industry. www.usnr.com | ISSUE 44 | Millwide Insider
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TECHNICAL SERVICE EXPANSION — FOCUS ON CUSTOMER SATISFACTION To help you get to know the Regional Service Manager for your region, following is a brief profile on each. Each Regional Service Manager and their respective teams will be responsible for all service, support and startups in their regional areas. If you don’t know them already, you will soon become acquainted as they work to support your USNR systems.
Keith Epp brings over 22 years of experience to his new role as Regional Service Manager for Western Canada, based at Salmon Arm, BC. Keith’s wealth of experience comes from employment at USNR acquisitions like Kockums Can-Car, Newnes Machine, CAE Newnes and Coe Newnes/McGehee, as well as other industry suppliers. Keith has been with USNR for the past 5 years. Prior to his work in this industry, Keith worked as a mechanic in the aircraft industry, machinist, millwright and welder, and gained education through a variety of college and university engineering and business programs. With such a broadly diverse background, Keith has performed roles at USNR that range from machine fitter, mechanical field service technician and outsource coordinator, to project manager, product line manager and now Regional Service Manager. “I really want to develop the Western Canadian service team to focus on supporting our customers in a dedicated and professional manner. We’ve always tried to do that, but I believe that as a smaller team focused on one region, we can work as a more cohesive unit to that end. To accomplish this, I want to develop a strong collaboration within our USNR departments, with the end goal for each member to achieve 100% customer satisfaction,” Keith explained. When Keith has an opportunity away from work he’s a true outdoorsman. He is currently working to develop a fishing resort near Bella Coola, up the coast of BC.
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A service and installation team works to install a new dry kiln.
A new sorter is underway courtesy of a service and installation team.
Milton Stahmer is the new Regional Service Manager for the US South region, based at Jacksonville, Florida. Milton came to USNR through the Inovec acquisition, now with over 20 years of tenure. Milton has a BS in Forest Management, with a minor in Business from Northern Arizona University. He also studied a variety of technologies through individual courses that covered electricity, electronics, PLC controls, hydraulics and pneumatics, and sawmill quality control. Before starting his career at Inovec, he worked for 18 years in the wood products industry at Gulf Lumber and Southwest Forest Industries.
In his career at USNR his roles have encompassed project manager, service manager, production manager, facility manager and operations manager. “I’m excited about helping to design a cohesive service organization to best support our customers. I want to strengthen our relationships with our customers, and expand our presence throughout the US South region,” Milton explained. Moving from being the Operations Manager in Eugene to Jacksonville will bring new adventures for Milton and his wife. He says, “Being new to Jacksonville and Florida, we look forward to exploring the area. In addition, being on the east coast we will be closer to family and I can pursue genealogy, studying and travelling to historical areas, and pampering our Greyhound.”
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TECHNICAL SERVICE EXPANSION — FOCUS ON CUSTOMER SATISFACTION
Renald Julien has taken on the role of Regional Service Manager for Eastern Canada and North Eastern US.
Renald comes to this role with a wealth of knowledge about sawmill operation and the industry, having worked at several mills and for other equipment vendors for many years, as well as formal education. He has worked for USNR for one year, starting in 2017. In 1986 he earned a degree as a forest technologist specialized in wood processing, from the College de L’Abitibi-Témiscamingue at RouynNoranda, north west of Montreal, Quebec. After graduation he went to work at several mills where he performed the roles of lumber grader, quality control, process optimization technician, and production supervisor. Renald also worked for another equipment manufacturer as Sawmill Process Specialist where he developed training material and training programs for customers. In that role he built a team of Wood Process Specialists to support customers’ training activities, to work with software engineers to develop features to meet customer needs, to test performances of each optimization system and upgrade, to assist project managers to scope projects, to perform acceptance tests with customers to close capital
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projects, and to provide technical assistance to the customers after projects were closed. In 2006-07 he went back to school and acquired a certificate in project management at HEC University of Montreal. Upon completion, Renald took on several roles at a hardwood sawmill as optimization technician, project manager, electrical supervisor, maintenance supervisor, operations manager, and maintenance manager. Renald’s plans for his new role at USNR include the following. “I want to contribute to advancing USNR’s presence with sawmills in our region, bringing professional assistance and technical support at a high level, to help customers meet their performance targets. I look for ward to working with my team to build a strong unit that will inspire each member to achieve their career aspirations. Renald’s life away from work includes hunting, fishing, and ATV and snowmobile riding. He also enjoys home renovations, and social activities with friends.
Tom Chambers is the new Regional Service Manager for the US West region, based at Eugene, Oregon. Tom’s career at USNR, like Milton’s, came through the Inovec acquisition, and he has been employed with USNR since 1999. Tom’s tenure at USNR has been in the Technical Service field throughout his 19+ years, first as Field Service Engineer and then Field Service Manager. Tom gained his technical background through the US Navy, as a Navy Electronics Technician for 9 years before starting with Inovec.
Jason Corkle is the Corporate Service Manager for USNR. He is based at Salmon Arm, BC.
Choosing to improve his education, he took a Robotics and Automation course at BC Institute of Technology, then worked at a lithium ion battery plant for a time. Jason started his career at USNR with the Newnes organization, in 1998. He was initially hired as an optimization field service technician, and spent 5 years in that role. He moved on to managing optimization upgrades, and then to managing the company’s 7/24 service support group. These roles were performed throughout the company’s transition from Newnes, to CAE Newnes, and to Coe Newnes/McGehee prior to the USNR acquisition in 2008. At the time of the acquisition, Jason was in charge of the entire service team including equipment for both solid wood and engineered wood processing sectors.
Jason’s tenure in the wood processing world began while he was still in high school, working at a local mill part-time. After high school he continued full-time, working his way through most of the processes in both green and dry operations. His last job at the mill was as a certified lumber grader.
In 2008 when USNR took over the company’s operations, Jason accepted the role of manager for customer service based from the Salmon Arm division. In 2016 he took on the role he holds today, Corporate Service Manager over all sectors. Jason explains the reason for setting up the regional teams within the USNR service network. “We created regional teams to better support our customers. USNR has
Tom says, “I really want to focus on customer relations. I plan to increase contact with our customers through enhanced phone support, onsite service visits and training our customers to get the most value from their installed equipment. Putting greater focus on cross training our team members will allow our service engineers to grow their knowledge base. In turn, this will provide customers the opportunity to have multiple machines serviced by a single engineer, increasing the efficiency and cost of our support services.” Another role that is close to Tom’s heart, is his role as father to 3 children. Much of his off-work time is devoted to their schooling and sports.
grown dramatically over the past decade, and one of the biggest struggles we’ve had is customers are sometimes confused about who they should contact when they need service, and where that support will come from.” He continued, “Our goal is to develop a small company feel within a larger organization, for customers. We want to foster closer relationships between customers and the team members in their region, and offer them support that resides in the same time zone they are in.” Jason described some other benefits customers will enjoy from this organizational change. “Having regional teams will mean we can deploy service technicians that will arrive much sooner than before, and customers will not have to incur as much in the way travel costs, so we will be able to keep costs lower. Another goal is to cross train our team members on all the equipment USNR manufactures, so each team will be able to service the broad range of equipment we offer.” When he has time off work Jason is an active dad to his 16-year-old son, and enjoys dirt biking and hiking, among other outdoor activities.
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Lumber Handling Technology
Cut-N-Two options for today’s mills INCREASE THROUGHPUT, IMPROVE YOUR BOTTOM LINE Many mills process boards that are cut in two or more pieces to add value to their output, or to meet their cut-to-order requirements. In North America and some other regions where there are a high number of grades, optimization is capable of extracting the utmost value from each board. Then handling a vast number of products becomes much more of a challenge. In these regions, traditional methods have improved the value of the products, but can reduce the volume of production. USNR has developed several solutions to mitigate the challenges. The traditional process When boards are identified for cutn-two processing, the lug loader deals an empty lug for each cut-ntwo board. After the trimmer cuts the board in two pieces, one of the resulting pieces must be transferred into the empty lug space. There are two common methods to achieve this. Lift skids can be installed in the flow to lift one of the cut-n-two board
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pieces and drop it into the empty lug space. The other method involves adding a recirculation transfer. One of the pieces is directed into the recirculation transfer and is deposited into an empty lug space. These processes come with several drawbacks. Creating empty lugs means reducing the mill’s overall production output, as a full-length board that is destined to be cut in two now requires two lug spaces.
If the mill wants to maintain its production level it must speed up the line. With a high percentage of cut-n-two solutions, the reduction in production or necessity to increase speed, can have major impacts on the operation’s process.
New designs USNR has developed several designs to overcome the challenges and allow mills to operate at the same rate of speed and production, while accommodating a high percentage of cut-n-two boards. After the board is cut in two at the trimmer, both pieces remain in the same lug space until sorted directly into the correct bin. The two pieces of the cut-n-two boards are ended to opposing lumber lines for sorting, and USNR offers two methods for accomplishing this.
Board ending
1
Board separation via hold downs
One method involves hold downs and opposing ending rolls after the trimmer. In the first section of the transfer, hold downs hold one piece of the board while ending rolls transfer the other piece to one lumber line. In the second section of the transfer, the ended piece is held in place and opposite ending rolls end the other piece to the opposite lumber line. Both pieces of the cut-n-two board share the same lug space, but at opposing ends of the transfer going into the sorter.
1
The second method involves temporarily splitting the flow at the trimmer outfeed. The clear line pieces of the cutn-two boards are diverted up an incline and even ended to the clear line. Meanwhile the lumber line board pieces and full-length boards remain on the lower deck, and are even ended to the lumber line. The two board pieces are merged again into the same lug space just prior to entering the sorter.
2
2a
Board separation via splitting the flow
2b
Boards merge into a single lug space before sorting
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LUMBER HANDLING TECHNOLOGY – CUT-N-TWO OPTIONS
Full Length Standard Bins
Split diverter shafts
Zones 1 & 2 Cut-n-two Split Diverter Shaft Bins
With this design, the sorter is divided into zones for sorting various products.
Sorting options As with board separation, USNR has two methods for sorting boards to accommodate cut-n-two boards in a smaller sorting footprint than would traditionally be required for additional sorts.
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in rl ea cl
The first sorting solution involves split diverter shafts in the sorter top. Each split diverter shaft has its own dedicated cylinder and valve at the nearest end of the bin. One portion of the split shaft actuates to pick out one of the cut-n-two board pieces, or both portions of the shafts actuate together for a full-length board. The diverter shafts can be split in differing locations for a variety of product mixes. With this design, the sorter is divided into zones for various products.
e
Split diverter shafts
Split diverter shafts
Zone 1 can sort 8’ or 10’ clear line boards.
As an example for a 20’ system, Zone 1 could be used to sort 8’ or 10’ cut-ntwo boards on the clear line side of the sorter. Alternatively it could sort 8’, 10’ or 12’ cut-n-two boards, or any length non-cut-n-two boards on the lumber line side. In the same example, Zone 2 would be configured with the split in the diverter shafts to accommodate sorting 8’, 10’ or 12’ cut-n-two boards on the clear line side of the sorter, or 8’ cut-n-two boards on the lumber line side. As with Zone 1, Zone 2 bins would also be able to sort any length of non-cut-n-two boards on the lumber line side. The two zones provide for handling cut-n-two solutions where the longer board is on either end of the original board.
Split diverter shafts
Zone 1 can also sort 8’, 10’ or 12’ lumber line boards, as well as full-length lumber line products.
Split diverter shafts
Zone 2 can sort 8’, 10’ or 12’ clear line boards.
Split diverter shafts
Zone 2 can also sort 8’ lumber line boards, as well as full-length lumber line products.
The full-length standard bins would accommodate full-length board products, with the option to also accept any cut-n-two lumber line boards. This section would be fitted with single bin diverter shafts and cylinders for each bin. Bin discharge chains would be configured to handle lumber line side and clear line side board pieces.
lum
ber
line
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LUMBER HANDLING TECHNOLOGY – CUT-N-TWO OPTIONS
Full Length Standard Bins
Tandem bin sorting
Cut-n-two Tandem Bins
Two short length sorters are located side-by-side with independent bin floors. A standard full width sorter is located behind either of the other side-by-side sorters.
Tandem bin sorting With a tandem bin sorting configuration, two short length sorters are located side-by-side with independent bin floors. They are contained under a single sorter top, with dedicated diverters, shafts, and floors for lumber line and clear line, as well as dedicated discharge chains with an interchange rollcase. A full width sorter is located behind either of the side-by-side sorters. With this example, for a 20’ system the clear line tandem bins accept 8’, 10’ or 12’ clear line products. The lumber line tandem bins accept 8’, 10’ or 12’ lumber line products. Clear line bins reverse discharge to an interchange rollcase, then travel on to the stacker in the same direction as the lumber line bins and fulllength bins.
Tandem bin sorting
The clear line (yellow) bins accept 8’, 10’ or 12’ clear line products. The lumber line (blue) bins accept 8’, 10’ or 12’ lumber line products.
Tandem bin sorting
Clear line bins reverse discharge to an interchange rollcase, then travel to the stacker in the same direction as the lumber line and full-length bins.
The full-length standard bins accept any full-length lumber line boards, with the option to accept any cut-ntwo lumber line boards. It shares the same sorter top as the tandem bins.
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Tandem bins, center exit This configuration is similar to the previous description for tandem bins, except that the floor chains for all the bins transport the lumber to the center of the sorter (pictured on page 18). Two short length sorters are located side-by-side with independent bin floors. They are contained under a single sorter top, with dedicated diverters, shafts, and floors for lumber line and clear line, as well as dedicated discharge chains with a center jump rollcase. A standard full width sorter is located behind either of the side-by-side sorters.
Tandem bins, center exit
The clear line (yellow) bins accept 8’, 10’ or 12’ clear line products. The lumber line (blue) bins accept 8’, 10’ or 12’ lumber line products.
Tandem bins, center exit
The full-width sorter will accept any lumber line (blue) products.
Tandem bins, center exit
All bins discharge toward the center jump rollcase. From there the lumber is transported on to the stacker.
With this example, for a 20’ system the clear line tandem bins accept 8’, 10’ or 12’ clear line products. The lumber line tandem bins accept 8’, 10’ or 12’ lumber line products. The full-length standard bins accept any full-length lumber line boards, and will also accept any cut-n-two lumber line boards. It shares the same sorter top as the tandem bins. The tandem and standard bins all discharge towards the center jump rollcase From there the lumber is transported on to the stacker.
Considerations The benefits of these options can be huge for mills that produce a high percentage of cut-n-two products. As the percentage goes up, the return on investment is increased. The configuration that may appeal to your mill will depend on factors such as space availability, cost of capital equipment, the number of products (sorts), and the level of product flexibility your mill requires to gain the highest return. Be assured, these configurations are all installed and operating in multiple locations, and we can arrange for you to view them first hand. USNR’s WinTally sorter management system accommodates any of these options, and MyMill mobile sorter control can make it easy to manage the wide variety of products you produce, from anywhere in the mill. When you’re ready, give us a call and we’ll help you design a system that is right for you.
To view videos demonstrating these configurations, please click the QR code, or go to: https://www.usnr.com/en/product/CutNTwo/videos
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L&B bandmill upgrades
Major improvement, low cost and impact BANDMILL GUIDE SYSTEM UPGRADES INCREASE SPEED, BOOST PRODUCTION A stud mill cutting Douglas Fir and Hemlock in the Pacific Northwest recently upgraded its 1973 L&B bandmill with the latest in automatic saw guide systems. This upgrade occurred in conjunction with some significant custom work to relocate the bandmill motors out of the tightly confined space below the bandmill, to a more open area that could accommodate larger motors.
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It was a major upgrade, and the mill took advantage of the downtime to do an upper sawguide conversion to further maximize guide precision and accuracy.
These workhorse L&B bandmills were typically designed with the motor housed beneath the wheel unit in a sloped sheeting area. This model usually runs 75-100 hp motors but the mill was running 125 hp motors, making the space underneath extra tight. Limited space and the amount of sawdust and chip debris from cutting wood, caused the motors to overheat too often. That inconvenience coupled with the fact that the mill wanted to further increase the motor size to 200 hp, so they could run faster on the larger pieces, caused them to reach out to us for a solution. The solution involved moving the motor up out of the pit to provide easier access and reduce the risk of blowing the motor from suffocation. There is also more space available up top to accommodate larger size motors. The process involved removing the upper guard assembly and cutting a hole through the bandmill frame to install a motor
base on top and a jack shaft underneath. A belt was then run down through the hole onto the jack shaft that drives the lower wheel. “We were able to use cog belts instead of v-belts,” said Kyle Morgan who engineered the project, “which are smaller and can transmit a lot more torque. They also have less slippage on higher horsepower motors, making an overall tighter functioning system.” Because the upper wheel guard on the original L&B bandmill wraps all the way around and connects to the base of the frame, new guards had to be installed to accommodate the motors. The single guard unit was split in two, creating an upper guard and a lower guard. USNR took the opportunity to include a spare belt in the lower guard so the mill doesn’t have to drop the wheel just to change a belt. This saves a huge amount of time not having to realign the wheel,
and a whole day of labor for the change-out. Kyle said, “Now they just remove the front plate off the lower belt guard to reveal hooks that seat a spare belt. This smart feature cuts the job in half.” Another small but significant convenience is all the belt sizes are the same length, so only one belt with one part-number is needed for all the belts that run between the motor, jack shaft, and band wheel.
Now they just remove the front plate off the lower belt guard to reveal hooks that seat a spare belt. This smart feature cuts the job in half.
The original configuration with the motors installed in a sloped sheeting area beneath the bandmill.
BEFORE
The upgraded configuration with the motors mounted on top to accommodate larger motors and solve the overheating problem due to the tight confinement.
AFTER
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L&B BANDMILL UPGRADES — BOOSTING YOUR PRODUCTION
USNR’s standard guide system with linear rails, and guide package with pivot arms, will maximize guide precision and accuracy.
Kyle noted, “It was a major upgrade, and the mill took advantage of the downtime to do an upper sawguide conversion to further maximize guide precision and accuracy.” This involved upgrading to our standard guide system with linear rails. The mill also opted for the guide package with pivot arm. The pivot arm moves up and down, travelling on a linear bearing that provides additional precision and accuracy. The mill was able to reuse their existing linear
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positioners, and realize the maximum benefit of this conversion in terms of accuracy and precision. Using linear positioners to drive the guide system enables the movements of the sawguide itself to be controlled by the PLC, which makes the system much more accurate and precise. It also allows for a saw blade deviation system to be added in the future if desired. This system tracks the movement of the blade on the wheels.
Many such projects are needed in the industry today but most don’t have the finances to support it. When mills work with manufacturers to find ways to improve equipment performance, solutions can be found that may permit them to run for another 10-15 years. USNR is proud to offer performance-enhancing upgrades with quick paybacks. Contact us to learn more about this, or other upgrades we offer.
Browder Veneer
Upping capacity, efficiency NORTH AMERICA’S LARGEST VOLUME HARDWOOD VENEER PRODUCER CHOOSES NEW COE-BRAND DRYER FROM USNR
It's been a big savings on overtime. Our other Coe dryers are older models, and this one is a lot more efficient on gas used, probably at least 30% more efficient.
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BROWDER VENEER – UPPING CAPACITY, EFFICIENCY
We got prices from several different vendors, but others were not of the same quality. We've always run Coe dryers.
In response to the growing influx of offshore veneer products, Browder Veneer ups its game with a new dryer to increase its capacity, and achieve efficiencies from labor and resources. The proven Coe-brand dryer takes its place alongside 3 older models, and sets the stage for bottom-line success. Browder & Sons Veneer is located at Thomasville, AL, and is arguably the largest manufacturer of hardwood veneer by volume, in North America. Bart Furrow became plant manager in 1987, later bought into the family-owned business, and in 2007 became sole owner. Today he owns the plant along with his sons, Jason and Matthew. The plant features 4 lathe lines and 4 veneer dryers, and processes around 40 truckloads of hardwood
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veneer each week . Species include red oak , hickory, white oak , and poplar or gum. Bart explained that the vast majority – 90% or more, of the products go into the hardwood flooring industry. In addition to its veneer production, Blacksheep Woodlands LLC was founded by Jason for logging to supply the mill, and purchases tracts of woodlands to harvest.
We received prices from several different vendors, but other solutions were not of the same quality.
Facing challenges head-on Bart says the North American industry’s greatest threat is from the entry of Chinese veneer imports to the US market. The plant’s employment was up to 200 in the past, but it is currently down at 140. While the company battles its competition, it increased its production with a fourth lathe and needed to similarly boost its dryer capacity to handle the flow. Bart explained the economics of the investment decision, “We wanted to save on overtime because we run two shifts around the clock. Our backup plan was that if the economy tanks we will save on overtime. Extra capacity with no overtime to pay out, would make the payment on the dryer.”
He continued. “We received prices from several different vendors, but other solutions were not of the same quality. We’ve always run Coe dr yers and we’ve always had a good relationship with Coe, now USNR. In our experience, USNR always stands behind their products.”
Much of the material processed is red oak which caused some issues early on, with being highly corrosive. Bart explained, “Some of the sheet metal on the dryer needed to be replaced as we run a lot of red oak, and it contains a lot of acid. The USNR team took care of that for us.”
Supply details
Big savings
The dryer selected is a 4-deck, 6-section dryer, with 1 cooling section. Each section is 6’ long, with a heated enclosed length of 36’. The heated and cooling sections are equipped with insulated floors, and the dryer uses direct-fired natural gas heat.
When asked about results from the new dryer, Bart said, “It’s been a big savings on overtime. Our other Coe dryers are older models, and this one is a lot more efficient on gas used, probably at least 30% more efficient. Our older Coe dryers date back to 1959, 1969, 1993, and we’ve updated them all, as required, with new burner systems.”
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BROWDER VENEER – UPPING CAPACITY, EFFICIENCY
Bart continued, “We are happy with the way the project went. My oldest son Jason had the vision of the mill expansion, and it worked. We had a lot of projects going on at the time, but everything went as expected.” He explained that the company installed a new chipper system at the same time as the dryer was being assembled. Bart gives credit to other team members for the successful outcome. “My brother, Kevin Furrow, was project manager, working together with Matthew Furrow and Russ Hogelin. Russ was contracted as the project engineer.”
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Looking ahead In response to market factors, Bart said the plant is considering updating its lathe system to allow for a thinner peel. Whatever the market brings, the Browder plant is ready to meet the challenges head on.
We've always had a good relationship with Coe, now USNR. In our experience, USNR always stands behind their products.
NEW PROJECTS Allegheny – Edger and Trimmer Optimization Allegheny Wood Products is investing in new optimization and scanning technology for its trimmer and edger lines at its mills at Kingwood, Norton and Princeton, in West Virginia. Trimmer and edger lines at Kingwood and the edger line at Norton will receive the latest USNR optimization release, as well as new scanner frames outfitted with BioLuma 2900L sensors. The edger line at Princeton is updating its edger optimization package to USNR’s latest release with new computer hardware, and re-using its existing scanning system.
Boise Cascade – Lathe and Drying Operations The Boise Cascade plant at Florien, LA is investing in new technology for its veneer peeling and drying processes. It recently installed a step feeder at the infeed to one of its lathe lines, updated the PLC controls on the same line, and installed a new 6-deck veneer drying system. Again focusing on its green end, its adding a new core drive and pre-charger on its No. 2 lathe, as well as a valve conversion for the lathe’s hydraulic digital carriage drive. The No. 1 lathe is receiving a new charger pendulum. The green end is also adding automation in the form of an NV4g scanning system, clipper infeed system, and clipper PLC controls.
Canfor – BioVision Edger The Canfor Southern Pine mill at Graham, NC is stepping up to visionbased scanning and optimization with edger BioVision. The existing scan frames will be modified to accept USNR’s cutting edge BioLuma 2900LVG sensors.
Conifex – Major Supplier Conifex recently made a $100 million investment and turned an idled sawmill into a new modern mill complex outfitted with best-in-class technology. USNR is proud to have been a major supplier on this project, and to partner with Mid-South Engineering to help bring Conifex’s vision to reality.
Hyne Timber – BioVision Sawmill Trimmers The Hyne Timber operation at Tumbarumba, Australia is updating two sawmill trimmer lines with vision scanning. This follows on the heels of two edger BioVision systems installed at this site several years ago.
Northland Forest Products – Multi-Track Fence Northland Forest Products at Fort McMurray, AB is installing MultiTrack Fences in its sawmill and planer mill operations. USNR’s Multi-Track Fence is the industry’s most popular solution for board positioning ahead of trimming.
Southern Veneer – Sequoia Sentry Systems Southern Veneer at Fitzgerald, GA is updating its veneer drying lines with several improvements. The company is installing two Sequoia Sentry moisture measurement systems that will improve the efficiency of the dryer, and the quality of veneer with better moisture detection accuracy. This system provides better control over the drying process. The company is also installing insulated floor panels and doors into two existing longitudinal dryers. These improvements offer better overall efficiency of the company’s drying operation.
Tolko – BioVision Edger Tolko is investing in a new BioVision Edger line for its sawmill at Armstrong, BC. The new line will comprise an unscrambler, Maximizer positioning infeed with dual fetchers, 4-saw edger, and closecoupled picker tailer. The optimizer is a BioVision system utilizing data from the new transverse scanner fitted with BioLuma 2900LV vision sensors. Also included is a MillTrak™ lumber flow control system comprising two sensors mounted above the unscrambler.
COMPLIMENTARY SUBSCRIPTION For your complimentary subscription to our Millwide Insider magazine e-mail subscriptions@usnr.com to join our mailing list, or go to www.usnr.com/en/page/Newsletters.
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PROFILE Mark Culpepper is Vice President, Turn-key Project Management, based at Hot Springs, Arkansas. Mark comes to USNR from MidSouth Engineering, where he worked for over 32 years, most recently serving as Vice President. Mark graduated with a BS in Industrial Engineering from the University of Arkansas in 1983, and is currently a registered Professional Engineer in several US states. During his tenure at Mid-South, Mark was involved as a project manager for over 25 greenfield and major brownfield sawmill projects. He has
UPCOMING EVENTS
also managed hundreds of other industrial projects involving wood pellets, LVL, plywood, structural wood products, and other industries outside of wood products. In Mark’s new role at USNR, he will direct and oversee the project management activities for all turn-key projects. His guidance will increase the strength of USNR’s turn-key team, and will increase the scale of its turnkey capabilities. Mark said, “I’m looking forward with great enthusiasm to taking on this new role, and helping to build this strong team within USNR.”
18–19 MAY Expo Richmond
29–31 MAY Maritime Lumber
11–12 JUNE ILMA
Richmond, VA Richmond, VA
Charlottetown, PE
Revelstoke, BC
22–25 AUG IWF
29 AUG–1 SEPT Holzmesse
Atlanta, GA
Klagenfurt, Austria
