Millwide Insider #48

Insider

THE MAGAZINE FROM USNR | ISSUE 48

IAL

A N G I L SSUE SPEC I

INTELLIGENT MACHINES, GROUND-BREAKING SOLUTIONS

BROADEST GLOBAL EQUIPMENT SUPPLY: FROM A TO Z

FLEXIBLE DESIGNS MEET CONTEMPORARY CHALLENGES

CONTENTS

Millwide Insider

INNOVATIVE SOLUTIONS

ISSUE 48

Whether you are looking for new technology to improve your yield, reduce your resource requirements, or expand your markets, USNR has the solutions and the talented resources to get you there.

This issue showcases USNR’s broad level of technology, capability, and expertise in articles about some of our recent projects.

Southern Veneer - lathe line upgrade . . ............................................................... 3

SUBSCRIPTIONS

Tel.: +1.250.833.3028 subscriptions@usnr.com EDITOR

Colleen Schonheiter colleen.schonheiter@usnr.com

USNR

Coastland - veneer dryer retrofit .. ........................................................................ 8

Woodland, WA: +1.360.225.8267

Browder Veneer - hardwood veneer dryer . . ..................................................... 13

24/7 Service: +1.360.225.8267

Hunt Forest Products - automated veneer grading .. ...................................... 18 Martco - veneer dryer installation innovation .................................................22 Coastland - green end automation . . .................................................................. 26

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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.

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.

www.usnr.com | ISSUE 48 | Millwide Insider

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SOUTHERN VENEER – RECOVERY RAMPS UP

We ran extra production leading up to the second phase so we didn't lose any production during the changeover.

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.

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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

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.”

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.

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 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.

www.usnr.com | ISSUE 48 | Millwide Insider

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BlockLogix: Evolution in lathe optimization More than 15 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.

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.

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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.

Multi-Point Diverter System Delivers dramatic production increases.

Visit us at

Hall 26 Stand D08

The Ventek-brand Multi-Point Diverter System (MPDS) uses data from the New Vision Nv4g veneer defect scanner to precisely track and sort trash into the haul back, and divert fishtail/randoms onto the trays.

The MPDS allows many mills to abandon complicated and maintenance-intensive tipples, belts, divert rods and the cumbersome transitions to multiple trays, by loading each tray from discrete divert points.

Customers realize significant recovery and productivity gains in many areas including improved random recovery, reduced sheet-width variance, down-time reduction, manpower reduction, and increased production. Contact us to put this advanced technology to work in your mill.

Millwide. Worldwide.

+1.360.225.8267

www.usnr.com

Coastland Wood Industries

Efficiency powerhouse RETOOLED VENEER DRYER: ECONOMIC, EFFICIENT OPERATION Coastland Wood Industries wanted to obtain a stateof-the-art drying system when it contracted with USNR to outfit its newly-acquired dryer with the most efficient technology available. Cognizant of stringent environmental standards, the economics of fuel costs and market forces, it achieved exactly what it was planning for!

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We’re hitting the production numbers that I expected, and it’s giving me efficient, balanced drying.

Coastland contracted with USNR for the retrofit of a used Coe Model M72 veneer dryer it had purchased from closed Tackama Forest Products, located at Fort Nelson, BC. Coastland had subsequently installed a new lathe in the Nanaimo peeling plant, and part of the plan for that investment included expanding the drying capacity at its Delta, BC facility. Manager Dave Powers noted that the “bones” of the dryer were good, so they decided it made sense to relocate and retrofit it for Delta.

Coastland Wood Industries, based on Vancouver Island at Nanaimo, BC, manufactures Douglas Fir veneer and roundwood cores. The company operates four facilities along the coast of British Columbia, Canada.

The Nanaimo facility sorts logs and produces veneer and cores, while the Menzies Bay facility at Campbell River, and the Howe Sound facility both weigh, sort, scale, store and barge the logs to the processing site.

The company’s drying facility located at Delta, dries and grades the veneer, and operates as the company’s distribution center where green veneer is either shipped direct, or dried before shipping to market.

Coastland processes its logs into veneer sheets of 1/10”, 1/8” and 1/7” thicknesses. The major market for Coastland’s dry veneer is the LVL industry, but it also feeds the hardwood and softwood plywood segments.

Until recently, the company’s Delta drying facility operated 3 dryers; 2 are longitudinal design, fueled by natural gas, and one is a re-dryer.

As part of his research prior to acquiring the used dryer, Dave had been to visit his colleague Doug Webb, manager of Thompson River Veneer Products (TRVP), in Kamloops, BC. The TRVP operation is also a veneer drying facility, operating a Coe dryer that was equipped with Automatic Dryer Exhaust Control (ADEC), Cooler Pressure Balance, and other advanced features. Dave was impressed with the dryer ’s efficiency and cost-effective operation, and decided that was what he needed for the Delta facility.

Dave commented, “ADEC is new to the Coastland operation. The other 2 dryers we have are longitudinal dryers, and this one is the first jet tube dryer we’ve installed. I was interested in the efficiencies of the jet tube design, which is the newest dryer design out there, as well as the efficiency of the ADEC system. My goal was to install state-of-the-art drying technology. We just ended up putting it on an older unit.” Coastland was not unfamiliar with USNR’s Coe equipment line; the Coastland Nanaimo peeling facility utilizes two Coe veneer lathes.

In addition to the dryer, Coastland also relocated a Coe

The wet end seal section is part of the Automatic Dryer Exhaust Control system (ADEC) added to the infeed of the dryer.

www.usnr.com | ISSUE 48 | Millwide Insider

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COASTLAND WOOD INDUSTRIES – EFFICIENCY POWERHOUSE

ADEC - BENEFITS

Significant increase in volume of dried veneer 8-10% More uniform dry veneer moisture distribution Higher quality veneer Reduced exhaust volume 10-15% Thermal energy reduction 5-10% Reduced hydrocarbon build-up Reduction of in plant emissions

This illustration shows air flow control with Cooler Pressure Balance.

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10-bin dry veneer stacker from the closed Fort Nelson operation.

USNR’s Coe veneer dryer includes a finely tuned control system with several outstanding and proprietary features that make it unique. USNR’s contract for this dryer project comprised erecting a wet end seal section that is integral to the ADEC system, as well as a Cooler Pressure Balance control system. The ADEC system requires a single point discharge into a customer-supplied pollution control system for dryer emissions control. The ADEC system automatically controls the total dryer exhaust volume. This allows it to maximize thermal efficiency of the dryer, keeping heated air inside the unit and exhausting the volume of fugitive emissions.

Here’s how ADEC works

A wet end seal section is situated at the feed end of the dryer, and fitted with an exhaust fan. The fan discharges to the ADEC’s exhaust stack, metering exhaust flow from the seal section. Special entry and discharge stop-offs control the flow of heated dryer air into the seal section, and control fugitive emissions from discharging back into the dr yer. A small gas burner is located at the seal’s exhaust duct, and provides a temperature boost to the exhaust flow, minimizing pitch buildup in the seal section.

A control loop is established between the ADEC fan and the PLC. The PLC receives signals from a thermocouple located at the wet end seal section, and also from a thermocouple located at the dryer ’s feed section that senses ambient plant air temperature.

The numeric difference between the sensor readings indicates the exhaust airflow from the dryer into the seal section, and a temperature set point is established. When the temperature rises above the set point the PLC increases the ADEC fan speed, reducing the flow from the dryer into the seal section. When the temperature falls below the set point the PLC slows the ADEC fan, allowing

more dryer air to flow into the seal section. This continually modulates the exhaust flow to prevent fugitive emissions and allowing excess heat to escape from the dryer.

Balanced cooling

Cooler Pressure Balance minimizes heated dryer air from entering the cooling section, and vice versa.

This not only improves efficiency by reducing heat loss, but helps reduce pitch buildup inside the drying and cooling sections. The PLC system controls the operation of the dryer ’s main fans, drive tower, zone temperatures, ADEC single point exhaust, Cooler Pressure Balance, veneer temperature, and the dryer feeder and unloader.

To accomplish the cooler pressure balance control the first cooling section (attached directly to the last heated dryer section) is specially modified as both a pressure seal and a cooler. Stop-offs are mounted between the dryer rolls to mechanically seal the first cooler section from the last dryer section. In addition to its main cooling fan, the discharge vent is fitted with a large exhaust fan and modulating damper.

Pressure sensing manifolds are mounted on each side of the stop-offs between the last dryer

section and the first cooler section, connected via a pipe to pressure transducers. The pressure transducers continuously monitor the differential pressure between the heated dryer and the cooler seal section. The signal from the transducer is processed in the dryer ’s PLC with a near zero set point, which modulates both the damper and the speed of the exhaust fan. The effect of this control is to maintain a near zero pressure differential between the enclosed dryer and the cooler section, minimizing heated dryer air from entering the cooler and cooler air from entering the dryer.

Efficiency achieved!

stack. This design actually has a damper on that one exhaust port. It’s keeping the steam and heat inside the dryer, and only exhausting to about 30%.”

Balancing the exhaust output with Coastland’s pollution abatement system was one challenge that was dealt with through painstaking tweaks to the ADEC fans. The other challenge was interfacing the ADEC components to the existing dryer that took engineering, construction and start-up efforts. Dave is satisfied with the results, “It’s doing everything I envisioned it would do. We’re hitting the production numbers that I expected, and it’s giving me efficient, balanced drying.”

Commenting on how satisfied he is with the dryer ’s operation, Dave says, “I know the dryer is efficient, and overall my gas usage is down. It is more efficient than the longitudinal dryers, for sure.”

Dave went on to explain, “I can tell by the damper position on the dryer that we are putting less flow out into the atmosphere. It typically runs at about 20-30% (open). That demonstrates the efficiency of the dryer. Depending on the design of your dryer and its damper controls, those exhaust ports may be open and all your heat is going out the

I know the dryer is efficient, and overall my gas usage is down. It is more efficient than the longitudinal dryers.

Watch animations that demonstrate how the Automatic Dryer Exhaust Control (ADEC) system and the Balanced Cooling control operate: https://www.usnr.com/en/product/veneerdryer/videos

www.usnr.com | ISSUE 48 | Millwide Insider

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Next generation grading is here.

The Ventek-brand New Vision Green Veneer Scanning System (NV4g) is our 4th generation system. It uses the latest machine vision technology to bring you significant recovery and productivity gains. Mills have reported a 1-2% increase in full sheets.

Specialized color cameras and spectrally specific LED lighting accurately and reliably separate good wood by grade, stain, wane, and defect. The NV4g allows for advanced clip strategies and applies grade classifications to clipped veneer based on user defined rules. Off-line analysis lets you finetune settings in “what if� scenarios without risking real wood.

It all ads up to our most powerful grading system. And it is serviced with industry standard parts shared in common with the GSc2000 Dry Veneer Scanner. Contact us to put this technology to work in your mill.

Millwide. Worldwide.

+1.360.225.8267

www.usnr.com

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.

www.usnr.com | ISSUE 48 | Millwide Insider

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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 USNR. In our experience, USNR always stands behind its 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 USNR. In our experience, USNR always stands behind its products.

Making your process more profitable.

USNR has developed new technologies that make the veneer drying process more profitable. Roll-in dryer installation dramatically reduces the outage time when replacing or lengthening a dryer. Automatic Dryer Exhaust Control (ADEC) reduces energy requirements and lowers exhaust volume while improving the quality of dry veneer. And Balanced Cooling significantly improves moisture detector accuracy.

When automated with the Ventek-brand NV4g green veneer grading system, your operation can enjoy dramatic recovery and productivity gains. Advanced clip strategies are being implemented that apply grade classifications to clipped veneer based on user-defined rules.

USNR’s Coe-brand veneer dryers are renowned for consistently producing high-quality veneer with a uniform dry moisture content and aesthetic appearance. Our systems offer the highest efficiency, using the least amount of energy while producing minimal exhaust. Contact us to learn more today!

Millwide. Worldwide.

+1.360.225.8267

www.usnr.com

Hunt Forest Products

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

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

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

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

Gaining insight

Previous decisions for the grading of veneer both at the green and dry ends of the process, were

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

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

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

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

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HUNT FOREST PRODUCTS – BETTER DATA YIELDS BETTER DECISIONS

Hunt Forests has two GSc2000 scanners operating side-by-side. The GSc2000

performs process data collection and interfaces to the plant’s remote management information system.

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

The enlarged sheet data explanation: DX (the grade assigned)

W= 49.80 (sheet width)

> New Grade D (the next higher grade)

L= 100.82 (sheet length)

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

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

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Why Ventek/USNR?

“Ventek (USNR) is a well-respected supplier to our industry,” said Richie.

“Our plant manager, Walter Wagner, had previously worked in facilities where Ventek scanners were installed. We made the decision largely based on Walter ’s experience and on information that the Ventek team provided.”

Making progress

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

We needed to better understand and get control of our processes.

We felt that automating the grading process would help us determine the best products that we should be producing for our market.

the clip parameters for trash, panel sizing and where to clip (combining defects or clipping the center of the defect), in order to optimize recovery, capacity and/or end product type.

Better data

Improving the quantity and quality of information from the production process was also a goal of the scanner upgrade, and the new NV4g scanning system provides production reporting including grade distribution, downtime and wood species processed. The system also allows for “virtual clipping,” using stored ribbon data, which gives the user the ability to test and change parameter settings before an actual production run in order to view the results and optimize clipping strategies based on market needs.

All system parameters and clipping strategies can be customized at the touchscreen operator interface and saved to tables. System diagnostic information is also readily available to machine operators and maintenance personnel.

Second phase

Six months after the new greenend scanner was installed, the plant installed two new Ventek GSc2000 dry veneer grading systems at the outfeed of the full sheet dryers.

Like the NV4g, the GSc2000 has a .060 in. scanning resolution. It also incorporates True Color vision technology, with industrial cameras and lighting to provide enhanced defect recognition through varying background color and changing light conditions.

“The GSc2000 provides better than 95% grading accuracy for the dry veneer,” says Chris Van Ackeren, USNR Account Manager. “Because the system is automated, grading decisions are made with a higher degree of consistency than before.”

“The scanners add objectivity that has helped us make better decisions,” echoes Richie LeBlanc.

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

Implementation

The real challenge implementing the new systems came post start-up.

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

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

Results

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

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RoyOMartin

Installation innovation GROUND BREAKING INSTALLATION PROCESS FOR AMERICA'S TOP PLYWOOD PRODUCER North America’s largest plywood manufacturing facility selected USNR to supply its new Coe-brand veneer dryer – a high production 6-deck system that outperforms others on the market. In the process a new innovation for dryer installation was taken from concept to reality – effectively changing the rules of the game for dryer installation.

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I told Alan we had to come up with a way to tear the dryer out and put the new one in in 3 weeks. We have another identical 6-deck dryer going in, and it will be assembled off-line and towed into place just like the last one.

When the largest plywood manufacturing facility in North America goes looking for a veneer dryer supplier they need look no further than USNR. This was proven to be the case with the first Southern Pine 6-deck jet veneer dryer installed at Chopin, Louisiana. With a successful project behind them, a few weeks after start-up RoyOMartin purchased a second, identical 6-deck dryer.

RoyOMartin's Chopin plant is one of the most advanced plywood manufacturing facilities on the continent. In addition to the two new 6-deck dryers, the site utilizes a USNR high speed lathe system and two 4-deck USNR dryers.

Chopin produces a wide array of panel products for a myriad of applications; siding, sheathing, underlayment, beaded decorative panels, concrete forming, radiant barrier panels, and more. It also produces top quality furniture-grade plywood and panels.

Staying with a winner

In September 2010 issue of Millwide Insider we told you about USNR’s Coe 4-deck jet veneer dryer that was installed at the Chopin facility. At the time, Jonathan Martin, chairman and CEO of the company, commented, “We’ve been very, very pleased with the production capacity of the machine. We reached the machine’s capacity within a week (of startup) with almost no issues, which is unheard of.”

“We were very pleased with dryers 4 and 5 which we bought from Coe. We had seen the results of the increased dry veneer capacity and improved quality of veneer, so we wanted to stay with the same manufacturer.” This latest veneer dryer project marks the 3rd Coe dryer installed at the Chopin complex, and speaks to the unwavering confidence the company holds for the Coe dryer technology.

New dryer design

This first 6-deck jet veneer dryer in the southern pine industry is the 4th 6-deck dryer built by USNR.

The Chopin dryer includes 18 drying sections (144’) long and is heated with thermal oil. Unique USNRdesigned pressurized fan shaft seals effectively keep the plant environment exceptionally clean.

The Chopin plant also invested in the proprietary Automatic Dryer Exhaust Control (ADEC) system. ADEC allows automatic control of the total dryer exhaust volume, and ensures efficient production and maximum veneer quality.

Cooler Pressure Balance and Veneer Temperature Control work together at the end of the process to ensure uniform temperature is maintained as the veneer exits the dryer, minimize pitch build up and maximize thermal efficiency.

Maintaining market momentum

Jonathan Martin was determined to take every advantage of the profitable market conditions, and looked for inspiration to achieve his goal to maintain the company’s

In any production plant the cost of under capacity or lost production is huge, so anything that can be done to minimize taking machinery out of service is beneficial to us.

We were very pleased with dryers 4 and 5 which we bought from Coe. We had seen the results of the increased dry veneer capacity and improved quality of veneer.

momentum in the market place.

Jonathan found his inspiration and took his idea to Alan Knokey, VP of USNR’s plywood and panel products.

Jonathan explained. “We’ve experienced a very good plywood market, so one of the major costs is taking that much production (about 1/3 of our dry veneer production) out for an extended period of time. I told Alan we had to come up with a way to tear the dryer out and put the new one in in 3 weeks.” He went on, “I’ve seen this done with major pieces of equipment in chemical plants. We build it off line, we roll it into place, we hook up the hot oil and electrical, and away we go.” Alan and the USNR engineering team were very excited about this new concept and the challenge it presented.

A new challenge

Clint Spangler, engineering manager for USNR’s plywood and panel division, was charged with directing engineering efforts for the project.

The opportunity was enticing, and he commented, “Our biggest challenge was designing the dryer in such a way that we would not pull it apart when we moved it into position. Dryers are typically erected in place, so this project involved designing a means of supporting the dryer for the initial assembly, for rolling it into position and for the final positioning.”

Randy Bullion, USNR mechanical engineering manager, designed the rail system the dryer was assembled

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ROYOMARTIN – INSTALLATION INNOVATION and transported on. “The rail system was designed using various sizes of beams to account for changes in floor elevation.”

Game-changing process

A typical new dryer installation can require 18 weeks of downtime; with this new concept the Chopin plant outage was less than 3 weeks. “In any production plant the cost of under capacity or lost production is huge, so anything that can be done to minimize taking machinery out of service is beneficial to us,” said Jonathan, adding that about 95% of the project went off without a hitch.

From USNR’s perspective, the biggest challenge was, in Alan Knokey’s words, “Getting up the courage to make the first pull.”

Dave Brown of BMI Contractors was contracted to erect the new dryer, demolish the existing dryer, and tow the new dryer into position.

Team effort

BMI Contractors, based at Salem, Oregon, has 30 years of history working with Coe Manufacturing and USNR. Dave Brown, president of BMI, said, “The relationship between our companies has always been symbiotic in that we help each other succeed. For us a win is when everybody is happy and with USNR equipment we are confident every project will be a win.” He went on to explain that BMI has installed 2 new USNR veneer dryers at Chopin, and both projects were winners. He also commended the Chopin mill personnel, “The RoyOMartin personnel are very knowledgeable and look for ways to improve the project.”

Moving day

He went on to explain that the major differentiator with this project was simply the

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Above: The new dryer is erected off-line, while the old dryer (not shown) was disassembled.

magnitude of the dr yer to be moved. “Other pieces we’ve moved rarely top 100,000 pounds. The new 6-deck dryer tipped the scales at nearly 1 million pounds.” After discussion with all parties involved he decided to opt for an abundance of horsepower; they mounted a large winch to the floor of the mill to provide the moving force. He said they expected the dryer would take several hours to move the 300 feet into position, but the job was done in under 45 minutes.

New project

With the success of this project behind him, Jonathan contracted with USNR for another dryer. “We have another 6-deck dryer going in, and it will be assembled offline and towed into place just like the last one.” Jonathan has a lot of experience with Coe equipment and working with USNR. “It’s been a very fruitful working relationship. I’ve done business with USNR for sawmill equipment and plywood equipment for 40 years.”

Above & below: The project is complete and the dryer is performing beautifully, while preparations are underway for the next dryer of its kind to take its place.

The ability to replace existing dryers by towing the fully preassembled new dryer into place significantly reduces the cost of a new dryer installation. This new process will undoubtedly change the face of many future veneer dryer projects, as other processors recognize the opportunity for savings in time and money. USNR is honored to have been entrusted with bringing Jonathan Martin’s vision from concept to reality.

Our biggest challenge was designing the dryer in such a way that we would not pull it apart when we moved it into position.

Scan the QR code to view a time lapse video of the dryer construction at the Chopin plant, or go to: https://www.usnr.com/ en/product/veneerdryer/ videos

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Coastland Wood Industries

Smoothing the flow SYNCHRONIZED VENEER SCANNING AND HANDLING INCREASES RECOVERY, THROUGHPUT By synchronizing the veneer production process and upgrading to the latest scanning and optimizing equipment, Coastland Wood Industries was able to increase production while reducing downtime and maintenance requirements.

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We're seeing better uptime and an increase in recovery for sure. On a volume basis, we were able to speed up the line by 20%.

Canada’s rainy Vancouver Island is known for its lush stands of Douglas Fir, which yield very high-quality veneer. The first steps in processing the local fiber are performed by Coastland Wood Industries, which operates three veneer lathe lines at the company’s 10-acre Nanaimo BC mill. The mill handles about 900,000 m3 of logs per year to produce veneer in thicknesses ranging 1/8,” 1/7,” and 1/10,” amounting to the equivalent of approximately 450 million square feet of 3/8” veneer per year. Seventy percent of the product is dried and the rest is sold green. Coastland sells 95% of its veneer in North America, with the balance sold into Asia.

Because of space constraints in Nanaimo, drying and further processing of the veneer is done at the company’s Delta, BC plant on the mainland. This creates some transportation challenges which add to product cost. Hence, it is critical that the Nanaimo operation run as efficiently as possible. “In order to overcome our transport costs we’ve got to be that much better at what we do,” said Doug Pauze, General Manager for Coastland’s veneer manufacturing operation.

Ventek GEM moisture meter

installed at the clipper, replacing an older moisture meter that was at the infeed of the stacker. This new GEM system allows Coastland to make clip size adjustments based on moisture content

New lathe spindle, primary tray and

strip tray controls, motors and drives

Why Ventek?

“We wanted the best technology to reduce downtime and increase efficiencies,” said Doug. “We have had good experiences with Ventek products in the past. We’ve always had a Ventek green scanning line, and we have Ventek equipment for dry veneer scanning at our Delta operation, so it was natural that we check out Ventek’s newest equipment, and it has proven to be the best available for our needs.”

The process

The veneer production process at Coastland starts with sorting, cutting and debarking the raw logs, followed by peeling the veneer to the desired thickness on one of three veneer lathes. The veneer is then clipped

The Upgrade

Over the last couple of years, the drive to improve their production processes at Nanaimo caused Coastland’s management to invest in an equipment upgrade that included installation of: Ventek Multi-Point Diverter System (MPDS), replacing two oldertechnology vacuum diverters

Ventek MPDS interface conveyors to strip trays

Ventek NV4g Green Scanner

& grading system to replace Coastland’s earlier version, New Vision 3000

We wanted the best technology to reduce downtime and increase efficiencies. It was natural that we check out Ventek's newest equipment, and it has proven to be the best available for our needs.

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COASTLAND WOOD INDUSTRIES – SMOOTHING THE FLOW

Above: The operator monitors the flow of veneer through the scan frame at the NV4g green veneer scanning system.

The project went seamlessly. It's probably one of the easiest projects we've ever done.

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to produce sheets. Veneer destined for plywood is directed to stacker #1 (5 bins). Low grade sheets destined for post and beam construction are directed to stacker #2 (also 5 bins).

Veneer quality decisions are made automatically on a sheet-by-sheet basis by scanning/grading systems that monitor the process.

Specific improvements

The goal for the Coastland installation was for each veneer line, from the lathe to the clipper table, to act as one unit. This involves synchronizing the speed of the various system components to run in lock step, which in turn minimizes ribbon breaks due to mismatched

The Multi-Point Diverter system downstream from the NV4g green scanning system, diverts scanned veneer to the appropriate destination - strip tray or clipper table.

peeling and tray control process speeds. Rather than running the lathe at full speed and then stopping it to wait on the clipper, the lathe is run just fast enough to keep the clipper full without stopping and starting as often. The smoother operation reduces downtime and maintenance requirements. It also eliminates ribbon breaks, which are common in systems that run asynchronously. Combined with a better-controlled and welltuned catch-up tray system, the synchronized processing allows the lathe to send more veneer to the clipper. Gaps in the clipper operation are held to a minimum, while clipping decisions made by the Ventek NV4g lead to more recovery, compared to older systems that may cause salvageable veneer to be trashed prematurely.

The same principle goes for the strip tray controls, which are designed to

operate just fast enough to maintain a constant flow of material. The new controls require less operator intervention and increase tray capacity by diverting the trash veneer at the MPDS, and by keeping tight positional control over veneer sheets as they pass through the system.

The new moisture-sensing equipment added to the line enables better and more consistent moisture sorting for drying gains at Coastland’s dry-end plant at Delta, BC. The operator interface for each line is designed so that it is extremely simple to tune and dial in adjustments such as belt speed and veneer quality change. Because the design is highly modular and uses non-proprietary components, new technologies such as PLCs or motor drives can be incorporated easily into the system in the future without concern for the issues of dealing with proprietary elements.

Results

“The project went seamlessly from our perspective,” said Doug Pauze.

“It’s probably one of the easiest projects we’ve ever done.”

The operating results of the line upgrades have been impressive.

“We’re seeing better uptime and an increase in recovery for sure,” said Doug. “On a volume basis, we were able to speed up the line by 20% and get higher capacity. We definitely met every goal that we were trying to achieve, and then some.”

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Our products have been installed in sawmills and plywood plants all over the world, from North and South America to Japan and Australia, from Africa to Europe and Russia. No project is too complex, no location is too remote.

USNR GLOBAL

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RECENT PROJECTS AB KARL HEDIN ÄLGSJÖ SÅG ALLEGHENY WOOD PRODUCTS ALLWEATHER WOOD ALMOND BROTHER LUMBER ALTA FOREST PRODUCTS ANAIKA SOINLAHTI TIMBER ANGELINA FOREST PRODUCTS ANGELO CREMONA ANTHONY TIMBERLANDS AO UGRA TIMBER HOLDING APOLLO FOREST PRODUCTS AS TEXTUUR AS VIIRATSI SAEVESKI ASHTON LEWIS LUMBER ASIA-LES ASPEN PLANERS ASSOCIATED KILN DRIERS ATA TIMBER BÄCKEBO SÅGVERK BALCAS TIMBER BALL LUMBER BALLINGSLÖVS SÅGVERK BALTIC FOREST BARRUS BATTLE LUMBER BEASLEY FOREST PRODUCTS BEGNA BRUK BENNETT LUMBER BERGENE HOLM BERGS TIMBER PRODUKTION BIEWER SAWMILL BIG CREEK LUMBER BILL HANKS LUMBER BLANCA FORESTRY PRODUCTS BLYBERG TIMBER BOIS CFM BOIS DAAQUAM BOISE CASCADE BRANXHOLM CMTP BRATTBY SÅGVERKS BREVER-BOIS S.A BRIGHT WOOD BROWNLEE LUMBER BSW SAWMILLS LTD BUILDING PRODUCTS BULLS BAY GROUP BYGLANDSFJORD SAG ANS CANFOR CARRIER FOREST CARTER HOLT HARVEY CHUGOKU LUMBER CHURCH & CHURCH LUMBER CLAUDE HOWARD LUMBER

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