Viiratsi Sawmill - Flexiblity, advanced automation

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.

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 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 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.”

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.

Pictured above: Catech Edger utilizing USNR optimization with BioLuma sensors.

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 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

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 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.”

With a peak capacity of up to 70 boards per minute, other vendors in Europe did not have an edger with such capacity.

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 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.”

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.

The core concept is the quad bandmill, through which the logs pass up to four times depending on log size and machine configuration.

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 edger. The cant is rotated 90 degrees before returning for the next pass.

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.