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Browder Veneer - Upping capacity, efficiency
from Millwide Insider #44
by USNR
Browder Veneer
Upping capacity, efficiency
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NORTH AMERICA’S LARGEST VOLUME HARDWOOD VENEER PRODUCER CHOOSES NEW COE-BRAND DRYER FROM USNR
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 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.
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 dryers and we’ve always had a good relationship with Coe, now USNR. In our experience, USNR always stands behind their products.”
Supply details
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.
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.”
Big savings
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.”
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.”
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.
