Forestry Industry | 2022 PLI Report

FORESTRY INDUSTRY MARKET AND PRODUCTION LINE INTELLIGENCE

Overview EPTDA was founded as the European Power Transmission Distributors Association in 1998 on the initiative of a group of power transmission and motion control (PT/MC) industrialists who believed in bringing together PT/MC distributors and manufacturers on one unique platform. It has since become the largest organisation of PT/MC distributors and manufacturers in EMEA and is one of the most powerful and respected B2B executive platforms for the industry worldwide.

EPTDA’s mission is to strengthen its members in the industrial distribution channel to be successful, profitable, and competitive in serving customers to the highest standards. The association takes great pride in its values which focus on being a premier community for qualified members through open dialogue and mutual respect; acting with integrity, honesty, and fairness; and ensuring continuous growth and learning.

EPTDA continually strives to develop relevant tools for its members, helping them stay competitive in a constantly evolving marketplace and business environment.

As part of the development of tools and resources for members, this document is designed to add value to their commercial understanding of specific markets and production line processes. This document, on the Forestry industry, follows reports on the Soft Drinks industry, Confectionery, the Automotive industry, Material Handling, Recycling and most recently, Aggregates.

Purpose of this document The purpose of this document is to provide distribution management and their sales forces with market and production line intelligence on the Forestry industry, primarily in the process from felling the tree to the manufacture of wooden planks, ready for the building industry and general carpentry. This document explores trends, identifies products used in the extraction of wood from forests, the transportation and laminating process; it clarifies key challenges, and considers the opportunities for distributors and how these can be capitalised, commercially.

This document has been divided into three parts:

1.

Industry Overview

Pages 4-13

This first section provides an introduction and overview to the Forestry industry and gives key background information, market intelligence, and major players within the industry. It has been organised as follows: a. Definition, segments within the industry, and market share b. Market size and coverage c. European sales data and evolution d. Current and future market trends e. Overview of challenges f. Key producers g. Major machine & system builders

2.

Production Line Intelligence

Pages 14-27

This section illustrates the extraction and processing of timber with a fully detailed production line schematic, so as to provide an understanding of what is involved and where the opportunities lie. Key customer challenges, major product groups, typical maintenance, and improvement projects are identified throughout the line, as well as highlighting potential areas of commercial opportunity for the distributor.

3.

Use of this Document

Pages 28-29

The opportunities within Forestry, both for MRO and OEM distribution, are significant – a minimum combined ‘scale of opportunity value’ (SOV) of 300m€ has been estimated as available for distribution of Power Transmission products in the sawmill aftermarket.

The final section proposes how the document could be used and provides open-ended questions that can be asked of prospective customers in order to reinforce the knowledge gained in parts one and two and to maximise the available opportunities.

3

PART ONE

Forestry Industry Overview Definition, segments within the industry and market share Forestry – defined as the management of trees and other vegetation in forests – is an important industry in Europe. Nearly 60% of wood harvested in Europe is then processed by European forest-based industries, accounting for around 7% of Europe's manufacturing GDP. However, contribution to Europe's total GDP is heavily influenced by region. Overall, the forest sector accounts for less than 1% of Europe's total GDP, but the Northern regional alone contributes over 40% of this.1 Looking at the global forestry and logging market alone - it was estimated to be worth 475bn€ in 2020 and is forecast to reach a value of 644bn€ by 2025 at a CAGR of 6.3%.2 This market consists of the sales of forestry products and logs by organisations that produce, harvest and/or process them, and are involved in growing, cutting and transporting timber; operations

of the timber tract; growing trees for reforestation; and collecting forest products such as gums, barks and fibres. With nearly 50% of land covered in forest and 60% of harvested wood processed in Europe, this is therefore a significant industry for the region.

In 2019, it was estimated that there are around 420,000 enterprises operating in forest-based industries in Europe. This includes pulp and paper, furniture, printing and bioenergy sectors. Representing nearly a fifth of manufacturing enterprises in the EU, together they generated a combined turnover of more than 520bn€.3 The forest products industry - consisting of industrial roundwood, sawnwood, wood panels, sheets and wood fuels - was estimated to be worth 105bn€ in 2019.4 Of which (and the focus for this PLI report) 76bn€ was generated by the sawmill industry - the extraction of timber and processing it into planks.5

Forestry materials are usually collected as: Whole trees

Whole trees from forests, plantations, orchards etc. include those harvested specifically for energy, those removed as part of commercial thinning operations, disease or death, and those removed to reduce forest fire potential.

Logging residues or primary forest residues Materials resulting from tree collection/harvesting operations and include treetops, twigs, and branches.

Processing residues or secondary forest residues Fine and coarse wood, sawdust and bark produced during wood processing at sawmills, veneer mills and furniture manufacturers.

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Market size and coverage Forests cover a total of 31% of the globe, a percentage which is decreasing. It is estimated that over the past decade, 4.7 million hectares (0.1%) of forests have been lost worldwide. In contrast, Europe has a higher coverage of forestry (46%), and specifically in Finland, Sweden, Slovenia, Estonia and Latvia, over 50% of land is covered.6 Europe accounts for approximately 5% of the world's forests and, contrary to what is happening in many other parts of the world, the forested area of Europe is slowly increasing.7 As of 2020, 23.6% of Europe’s forests were in protected areas with most European forests having designated management plans in operation, and the highest percentage globally of forestry management plans.8 Globally, approximately 30% of forests are used primarily for production, with Sweden being the largest forestry product producing country in the world, tied with Canada.9

Approximately 1.1m3 of wood is consumed per capita in Europe.10 Much of this demand is from the construction sector, however this slowed down during the COVID-19 pandemic when many construction activities were forced to halt work.

During this time, there was instead a surge in demand for paper, paper products and packaging, as online shopping and deliveries increased significantly.

Alongside a high proportion of forest coverage, there are over 650 sawmills operating in the EU.11 Whilst 25% are based in Sweden alone, across the remaining EU-member states, there are on average nearly 20 sawmills. These sawmills, in turn, are heavily relied upon by forest-based industries, including woodworking; pulp, paper and paper products; printing; construction; furniture products; and wood bioenergy (often interlinked with other industries).

Land area covered by forests in Europe in 201912 Country/region

%

Country/region

%

Country/region

%

Country/region

%

Finland

66

Spain

37

Germany

32

Denmark

15

Sweden

64

Portugal

36

Italy

32

United Kingdom

13

Slovenia

58

Bulgaria

35

Poland

30

Ireland

11

Estonia

54

Luxembourg

34

Greece

30

Netherlands

8.9

Latvia

53

Croatia

34

Romania

29

Malta

1.5

Austria

46

Czechia

34

France

27

Slovakia

39

Lithuania

34

Belgium

22 EU overall

38 %

Sawmills operating in Europe13 Country/region

No.

Country/region

No.

Country/region

No.

Country/region

No.

Sweden

184

United Kingdom

19

Czechia

7

Ukraine

3

Finland

92

Denmark

18

Romania

7

Slovenia

2

Germany

82

Switzerland

18

Italy

6

Bulgaria

1

Austria

46

Estonia

16

Slovakia

6

Hungary

1

Russia

38

Latvia

15

Spain

6

Netherlands

1

France

33

Poland

13

Belgium

3

Norway

25

Lithuania

11

Ireland

3

5

Gross value added to EU economy by country in 2018 (million Euro)14 4500 4000 3500 3000 2500 2000 1500 1000 500 0

Finland

France

Germany

Sweden

Italy

Romania

Poland

Czechia

Austria

Spain

In 2018, over 500,000 employees worked in the forestry and labour sector, a 2% decrease since 2000. Poland employs the largest workforce, followed by Romania, Sweden, and Germany respectively. However, productivity of labour is heavily influenced by the size and locations of the forests, as well as the labour intensity of the sector.15

Employment in forestry and forest-based industries is of significant importance to rural areas where most forests are located.17 Regional differences such as this are highlighted by labour per hectare of forest where in Norway and Sweden there is one person per 1,000ha compared to in Hungary, Slovakia and Republic of Moldova with over 10 persons per 1,000ha of forest.

Of those working in forestry and forest-based industries, 36% are employed in the primary forestry sector, 40% work in wood manufacturing, and approximately 25% in paper. However, this varies according to region. For example, in many South-Eastern countries in Europe employment is greater in the primary forestry sectors compared to Central Europe where there is greater employment in wood working and paper-based industries.16

This is a result of the increased automation and mechanisation utilised in Northern Europe, as well as the physical makeup of forests and their accessibility. This is again reflected in the Gross Value Added per employee which is significantly higher in Northern and Central-West Europe where there is increased mechanisation.

Growing stock in Europe by main species18

Fir 3%

Pine

Other 15% Pine 30%

Birch 7%

Spruce Beech Oak

Oak 10%

Birch Fir Beech 12%

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Spruce 23%

Other

Profiles of the top three species of trees Scots Pine19 | Pinus Sylvestrus Type

Coniferous

Size

23-27m average height

Lifespan

Up to and over 400 years

Characteristics

Orange bark on upper stem, blue/grey-green needles 5-7cm long in pairs, can tolerate cold, drought and poor soils, cones carrying seeds are green and ripen to brown after two years.

Wood

Softwood – one of the strongest, with a good strength to weight ratio. Easily workable. Lasts well in wet conditions. Commercially and economically important, particularly to Nordic regions.

Current uses

Sawn timber for building, construction, furniture, pulp and paper.

Due to its plant hardiness in poor soils it is also planted for land reclamation, anti-erosion and windbreaking.

Norway Spruce20 | Picea abies Type

Coniferous

Size

Up to 50-60m height, up to 150cm diameter trunk

Lifespan

200-300 years

Characteristics

Orange-brown bark, creamy white wood, cylindrical 12-15cm long cones are green then turn brown in autumn.

Wood

Softwood – easy to work if no knots are present. Not particularly durable, decay-resistant or tough.

Current uses

Solid wood for timber construction; pulpwood for paper; joinery timber; furniture; veneer; tone-wood (sound boards of pianos and the bodies of guitars and violins); most common Christmas tree.

European Beech21 | Fagus Sylvatica Type

Deciduous

Size

30-40m average, 50m maximum

Lifespan

150-300 years

Characteristics

Single-stemmed, silver-grey barked trunk; high growth rate until mature age; leaves are elliptic, dark green and shiny.

Wood

Hardwood – strong, fine-grained, knot-free, pale cream colour, bendable and easy to work, wear-resistant.

Current uses

Having approximately 250 known usages, its diversity makes it one of the most important species in Europe. It is ideal for boatbuilding, flooring, stairs, furniture, musical instruments (piano pinblocks), plywood, panels, veneering and cooking utensils such as bowls, platters and wooden spoons. It is also used for pulp and can be coppiced for firewood and charcoal due to its high energetic potential.

7

European sales data and evolution Construction Accounting for over 43% of the global forestry and logging market in 2020, the construction segment is the largest segment by end-use application. It is also expected that this segment will be the fastest growing segment in the coming years, at a CAGR of 10.3%.22 Wood used as a building material is increasing due to numerous advantages of wood buildings over concrete buildings, and promotion by governments and the industry itself, thus driving the market for forestry and logging producers.

Presently, the building industry produces 25% of global greenhouse gas emissions and therefore the concept of green building construction has evolved, expected to reduce CO2 emissions and store carbon. Wood-constructed buildings also produce less waste and can be constructed more quickly than concrete buildings.23

Forest bioenergy Forest-based bioenergy is a common coproduct of the forestry industry and is the second most important biorefinery method in Europe after agricultural feedstock. It can be done using either primary forest materials (collected with the specific intent to use as bioenergy) or secondary forest materials (collected as a byproduct of other forestry activities).

Additional biomass for energy may be derived from harvest slash (e.g., branches, tops, stumps) that would otherwise have decayed in the forest. This tends to be a low-value product compared with other forest products, and thus not traditionally a primary driver in determining forest management and harvest scheduling.

Of forestry-based biorefineries in EU member states, 57.1% use primary biomass (materials specifically for creating bioenergy) and 42.9% use secondary biomass (converted or decomposed forest materials).24 As of 2017, nearly 80% of wood energy is consumed almost equally by industry (39.3%) and end consumers (40.3%). The power and heat sector account for a large share of the energy

Sawnwood production and consumption in Europe (million m3)26

Forestry-based biorefineries are spread somewhat evenly across Europe, though there are a considerable number in both Finland and Sweden. Finland and Sweden, as well as Portugal, appear to also have more extensive biorefineries and biorefinery methods.

In 2017, of 31 countries in a study, wood energy accounted for 3.8% of total primary energy supply and 35.4% of renewable energy supply – the highest source of renewable energy. Woody biomass meets 26.2% of primary energy demands in Finland, 19.6% in Estonia, 19.3% in Sweden, and 17.3% in Lithuania.

In terms of renewable energy supply, woody biomass accounts for over half the supply in Austria, Belarus, Czechia, Estonia, Finland, Lithuania, Serbia, Slovak Republic, Slovenia, and Ukraine. Nearly 43 of total mobilised woody biomass is used for energy purposes.25

Roundwood production in Europe (thousands)27

600

86 84

500

82

400

80 78

300

76

200

74

100 0

produced e.g., black liquor produced during the kraft pulping process is used by the forest industry in wood processing.

72 70 Europe

Worldwide Produced

Consumed

68

2015

2016 Removals

8

2017 Consumed

2018

2019

Wood-working production by sector, 201828 7% 18%

29%

Wood and wood products Furniture products Pulp, paper and paperboard Printed products

23%

23%

Bioenergy

Current and future market trends Effect of COVID-19 on consumer behaviour The global pandemic has resulted in a significant increase in consumers’ online shopping and delivery orders during government-imposed lockdowns that required them to stay at home. This has resulted in a surge in demand for paper packaging used for both online orders and food deliveries. For example, over 2014-2019, e-commerce revenues in Germany grew by 63%, and the COVID-19 pandemic created more incentives for businesses in Europe’s biggest economy to adopt e-commerce and increase their presence online, as most retail outlets shut their doors in spring 2020.

The world’s largest e-retailer, Amazon, which accounts for more than a quarter of all e-commerce sales in Germany, reported an increase in sales of almost 26% in the first quarter of 2020 compared to the same period in 2019.

The coronavirus outbreak hit Europe very unevenly. In countries where the economy was more resilient – such as Scandinavia and Germany – and where the construction market held up better than expected, the sawmill industry has been navigating the crisis quite well. Some segments, such as the DIY sector and home improvement did very well as people spent more time at home and on home improvements. Other countries, such as the UK and those in Southern Europe had a much harder time with construction markets being more severely impacted and sawmills in some cases forced to suspend operations.29

Effect of COP26 on consumer behaviour There is heavy pressure from both consumers and governments on corporations to put greater focus on the environmental impact of their activities; the EU’s aim for carbon neutrality by 205030 possibly having the largest effect as it regulates many aspects of the forestry industry. As a result, many organisations in forestry and its related industries are committing to sustainable forestry efforts and tree planting initiatives in order to offset their own environmental impact. For example, the European Organisation of the Sawmill Industry (EOS) includes most EU countries and aims to creates sustainable practice in the sawmill industry. Even tech giant Apple invested $200 million into forest restoration and planting initiatives as part of their goal to reach carbon neutrality by 2030; and UK-based global brewery Brew Dog achieved carbon negative status in 2020 through its partnership with Eden Reforestation Projects.

Although wood and wood-based products are used every day as paper, furniture, in construction, for packaging, and in many other areas, including renewable energy; today we are using much less wood compared to the growth of the forest. EU forests have been a continuously growing natural resource in the past 75 years. However, there are doubts as to the longterm benefits of this, as much of this growth has occurred in warmer, drought-prone regions of Europe. As a result, the expanding forests’ productivity and quality plateaus where there are insufficient water levels to accommodate them. This has been the case in the US where farmers have begun cutting down neighbouring trees as they are depleting the water in the region’s soil.31 The average harvesting rate of the Net Annual Increment (NAI) of forests available for wood supply is officially estimated to be at 63%, with differences among countries. This means wood industries can grow whilst maintaining, or increasing European forest resources. The sustainability of the NAI in Europe can be greatly seen by the European figure of import reliance for industrial roundwood, which has stayed below 10% in the last 15 years.32 Of 20 regions surveyed around the world, the EU was the largest producer of roundwood (sometimes referred to as removals, which consists of all wood removed from forests, other wooded land, and other tree felling sites) and sawnwood.

In 2018, roundwood production in Europe was at 650 million m3, making up 32% of global production. This was followed by the Northern America (USA + Canada) and Asia-Pacific regions, who both produced 519 million m3 each.33

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Sawnwood production in 201834

Did you know?

EU 22%

Rest of world 43% China 18%

US 17%

Challenges Although they are continuing to grow, there are significant threats to European forests. The main challenges being faced are environmental issues regarding forest health and other related economic factors. There are also challenges which pertain to the EU forest strategy for 2030 – a key initiative of the European Green Deal which aims to reach carbon neutrality by 2050. The strategy will contribute to achieving the EU’s biodiversity objectives as well as a greenhouse gas emission reduction target of at least 55% by 2030 and climate neutrality by 2050. It recognises the central and multifunctional role of forests, and the contribution of foresters and the entire forestbased value chain for achieving a sustainable and climate neutral economy by 2050 and preserving lively and prosperous rural areas.35

Workforce knowledge and experience Forestry is currently suffering from an aging crisis where a large percentage of its workforce is reaching retirement age and the industry is struggling to attract enough young workers to replace them. This has been further compounded by the global Precision Forestry industry - using tools and technology for site-specific management - which has seen considerable growth as the forestry industry strives for technological advancement that will improve efficiency and lesson the need for larger workforces in forestry. The global precision industry is estimated to be worth 7.2 billion€ by 2024.36 As a large proportion of the workforce reaches retirement age, the depth and range of knowledge of the specialist areas in the 10

It is possible in a single sawmill to find 20km of one type of chain with assorted fittings. industry, and the production line / processing, is not as extensive as seen in the older workforce, especially as the reliance on advanced technologies increases. For example, knowledge of the specification and requirements of specialist attachments in chain is heavily required in the processing of timber.

Forest health and raw material supply The European forests, particularly in Central Europe, have been affected by a bark beetle proliferation caused by several factors including climate change. According to recent studies, damaged wood due to bark beetle may reach in total 750 million m3 between 2017 and 2026. The European Sawmill Industry has voiced the importance of providing real-time, comparative, science-based and balanced information on European forest resources aiming at forecasting changes and their consequences on forest’s health and raw material supply.37 Root rot is another common issue affecting the health of forests and their ability to produce healthy, usable wood materials.

The challenge faced is how easily the rot spreads via root-toroot contact, affecting neighbouring and next generation trees.

Methods to combat this threat include maintaining the condition of tree bark and cutting during winter months when the fungus is less active. In Sweden, 15% of Norway spruce (the most common native species and most susceptible to root rot) have shown decay resulting from the fungus. The estimated cost of root rot to Swedish forestry is 1 billion Swedish Krona – nearly 100 million€.38 Poor quality wood results in lower value, and often logs are even unusable as timber etc. Given that these trees may have been growing for decades or even centuries, this is also a huge loss in terms of time and land use.

Innovation

Site management and working environment

Forest modelling and forest visualisation is carried out to survey land and existing forests in order to practice better management of forests and their ecosystems. Doing so enables forests to be planned, mapped and constructed according to appropriate soils, natural environments, climate, and the needs of the forestry industry. To implement forest modelling and visualisation, a variety of technology and tools are necessary, many of which are often in short supply or need further development.

Given that approximately 12.5% of delay time in most sawmills can be attributed to the running out of logs, efficient handling of raw materials in the receiving yard and proper routing of finished products is vital for forest-based industries. Wood-yards must be designed to facilitate rapid separation of species and wood type to aid uniformity of the final products and improve energy consumption during handling and processing.

Mixed species forests, or simply mixed forests, have proven to result in more productive and fast-growing forests because of their resilience to changeable climate conditions. However, it has also shown to affect the quality of wood and logs produced, particularly in the quality of knotted wood surfaces.

The sustained yield concept aims to consistently produce more than the loss from disruptive means such as fires, insects, disease, etc. This is often done through replanting of seeds, seedlings, and cuts, in accordance with a calculated rotation period.

Rotation periods for pulpwood for example, may be estimated at approximately 50 years, whereas softwood sawlogs typically require 100 years, and broad-leaved trees (like central Europe’s beech and oak) may require as many as 200 years to mature, making the sustained yield practices integral to ensuring supply.39

For example, Metsä Fibre - a producer of pulp, sawn timber, and bioproducts - is building a new sawmill in Rauma, Finland. Metsä Fibre hopes that this new sawmill will produce around 750,000 cubic metres of pine sawn timber each year, thanks to machine vision and artificial intelligence. It will also enable the 100 direct employees at the site to move from workstations around the production line to control room monitoring.40 Another significant challenge for sawmills to consider is the working environment and ability to process the natural resources that may have imperfections or impurities that can affect machine operations and required maintenance, such as strong bark or excess branches. As a harsh environment, all equipment and components must be able to address these challenges.

Key producers* in the forestry industry41 Rank (as of 2020)

Company

Headquarters

1

Stora Enso

Finland

18

4,690

2

Binderholz

Austria

8

3,180

3

Vida Wood

Sweden

12

2,350

4

Pfeifer Holz

Austria

5

2,080

5

Moelven Group

Norway

15

2,060

6

SCA Timber AB

Sweden

5

2,000

7

HS Timber Group

Austria

4

1,980

8

Mayr-Melnholf Holz Holding AG

Austria

3

1,950

9

Rottenmeier Holding AG

Germany

5

1,900

10

Södra Timber

Sweden

7

1,900

No. of sawmills

Production in 2020 (1,000 m3)

*Producers included in this list may also operate in other related industries such as paper or packaging, as well as in the processing of timber.

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Major machine & system builders There are over 7,200 manufacturers of machinery used for forestry and agriculture in Europe, with a 30% market share, equating to 2.4 billion€. Global demand for forestry equipment is rising, with a projection of exceeding 11.5 billion€ by 2027.42 The forestry equipment market is usually segmented by product type – felling, extracting, onsite processing, and other forestry equipment. Chainsaws, harvesters, and feller bunchers are all part of felling equipment.43 It is worth noting that across Europe the spread of machine equipment manufacturers and builders can be quite varied.

For example in Austria and South Germany there are a higher number of smaller manufacturers, whilst other regions in Europe may be more heavily saturated with larger organisations.

C. Gunnarssons Verkstads (CGV) AB | www.cgv.se | Vislanda, Sweden44 Providing machines and equipment to the sawmill industry for over 60 years, CGV primarily operate in the European market.

Machine and equipment include dry sorting and high-speed planer mills. With expertise in sorting, they also work with customers to develop automation systems to improve controlling sorting facilities for increased capacity and greater efficiency.

Docma S.r.l | www.docma.it | Verona, Italy45 Operating across the agriculture, forestry, construction, and mining industries, Docma specialises in the manufacture of winches, log-splitters and saw benches. Located in Verona, Italy and with over 20 years of experience, they provide portable machinery for the early stages in the production of timber, where logs are felled and collected for taking to the sawmill.

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Dragon Machinery | www.dragon-machinery.co.uk | Oswestry, United Kingdom46 Whilst predominantly providing shredding, shaving, and recycling services, Dragon Machinery manufacture and design a range of sawmilling and specialised timber processing machinery for waste wood to be shredded according to input size, type, volume and output size required. Dragon Machinery also offers a bespoke design service for other sawmilling applications, such as log decks, step feeders and log hauls.

Heinola Sawmill Solutions | www.heinolasm.fi | Heinola, Finland47 Part of the Lifco AB Group, Heinola Sawmill Solutions manufacture bespoke drying kiln solutions, as well as chippers for sawmills to create high quality fuel chips, and large drum chippers for the pulp and paper industry.

AS Hekotek | www.hekotek.ee | Harju Maakond, Estonia48 Also part of the Lifco AB Group, Hekotek are one of the leading manufacturers of machinery used in sawmills, offering a complete turnkey solution, such as log sorting lines, conveyor systems, board handling lines and log infeed lines. Based in the Baltic states, Hekotek supplies sawmill equipment across Europe. In 2020, they reported sales of c. 2,500 million SEK.

Henkon Forestry B.V. | www.henconforestry.nl | Ullft, Netherlands49 Built in the Netherlands and Italy, Hencon Forestry manufacture forestry tillers and rotavators, wood clamps, tree shears and chain saw systems for the collection of wood in less accessible areas. In addition, their range extends to the biomass industry for the collecting, chipping and grinding of trees and forest residue.

Kallion Konepaya Oy | www.kara.fi | Laitila, Finland50 A leading manufacturer of one-blade circular sawmills, Kallion Konepaja Oy’s brand– KARA – has a selection of cross-cut saws for trimming, crosscutting and component cutting of timber, as well as processing waste wood and slabs for firewood. The brand has over 100 years of expertise in saw technology and has expanded from saw blades to designing and developing complete sawmill lines and solutions.

Ledinek | www.ledinek.com | Hoče, Slovenia51 As a group of four companies, Ledinek position themselves as experts in the complex processing of large wood, planing and profiling, finger jointing and design, delivery and installation of cross laminated timber panel production lines. They also provide specialised solutions for the automation of destacking, quality grading and marking and conveying systems.

Primultini s.r.l. | www.primultini.com | Vicenza, Italy52 Providing a complete solution for sawmills, from timber handling and conveying to debarking, measurement and sorting, the Primultini Group also specialise in band saw blades through their brand Mec-Legno and automation services with the brand PriBo.

Raute | www.raute.com | Nastola, Finland53 A global market leader in technologies for plywood and laminated veneer lumber, Raute manufacture equipment for the processing of timber into engineered wood products. From their European offices in Finland, they offer complete turnkey solutions, as well as individual components and automation technology such as machine vision and analysis. In 2020, Raute reported sales of 115 million€.

SERRA | www.serra-sawmills.com | Rimsting, Germany54 As well as forestry machinery and equipment for the gathering of timber, SERRA manufactures sawmills with computer-assisted 3D programs for a bespoke solution. In addition, they offer edgers and resaws to process sideboard and main boards across slats, beams and boards, depending on the need, and to help relieve the reliance on the main saw alone.

TKM GmbH | www.tkmgroup.com | Remscheid, Germany55 More than just “knife manufacturers”, TKM operate across a variety of industries including paper, print and packaging, metal, plastics, food and the wood industry. TKM manufactures saws and industrial knives such as circular saw blades for precutting, profiling, edgers, chipper canters, and accessories. Their extensive knowledge of knives is paramount for identifying the right knives and accessories to use for the intended material and to reduce the risk of tarnishing and stains on the finished product.

USNR | www.usnr.com | Söderhamn, Sweden56 Prior to being acquired by USNR, Söderhamn Eriksson specialised in log lines and edger systems. Now as part of USNR, the range extends to complete end-to-end solutions for sawmills and planer mills. USNR also produce equipment for the manufacture of plywood and other panel products, and products to scan, grade and handle veneer and panel products.

Uniforest | www.uniforest.com | Prebold, Slovenia57 Manufacturing forestry machines such as winches, log splitters, crane grabs, and circular saws, Uniforest is a leading manufacturer in the forestry industry. Their products are primarily used in the collection and initial preparation of timber before it is transported to the sawmill for processing and finishing.

Wood-Mizer Industries | www.woodmizer-europe.com | Koło, Poland58 A world-leader in portable and stationary narrow band sawmill and bandsaw blades, Wood-Mizer is well-known across the forestry and sawmill industries. From forest to sawmill, WoodMizer produce machines used throughout the production process, including vertical saws, resaws, edgers, planers, slab flatteners, blades, and maintenance. They also can design smart-log processing lines, identifying opportunities to automate elements of the production line.

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Production of timber

Process

PART TWO Sawmill production line market intelligence

4. Sizing and sorting Logs are scanned, measured and graded, and sorted according to species, diameter, length and end-use.

sorted logs

log deck

scanner

4

Introduction This schematic describes the typical process used for the processing of timber from extraction to the sawmill.

Infeed, scanning and sorting

This process, whilst being typical, does not represent all processing and extraction of forestry. This is because actual plant processes may vary according to the desired end product - for example construction, paper and furniture.

Debarking 5. Debarking Logs are debarked using mechanical ring cutters, cambio drums or waterjet blasters. This safeguards saws and other equipment from undue wear and damage that would otherwise result from stones, metal and other contaminants embedded in the bark.

5

6

7

edger debarker

Any logs with remaining metal are sent back for a secondary examination. If the metal can be removed the whole log continues down the production line. If not, the log is salvaged in small sections.

6. Waste conveyor Unused bark from the debarking process is stored and burned for heat energy used in the drying process. This typically accounts for 70-90% of total energy consumed in the sawmilling process.

14

waste conveyor

7. Breaking down An initial saw sees the log broken down into slabs, flitches and cants. This sets a flat surface to square the work for secondary cants that turn into rough sizes for finished lumber products.

Waste sections, or slabs, are recycled into chips, pellets, or mulch.

Process 3. Infeed

2. Transportation

The felled logs are received by the sawmill and transferred onto the log deck by heavy lift trucks, derricks or cranes depending on the logs' dimensions and weight.

3

Vehicles equipped with lifting gear and grabbers transport felled logs to the sawmill.

Alternatively, if available, logs are sometimes transported downstream, by river.

1. Felling Loggers cut or fell standing trees, before being loaded for transport to the sawmill site. Winches and saws are occasionally used on site when in tight-closed spaces.

2

1

Collection of raw material

Log ladder and sawing

8

9 headsaw fixed saw

log ladder / carriage

8. Headrig / primary breaking down A log ladder/carriage conveys the log through the headsaw (head rig) on which the log may be clamped to a conveyor and turned. Depending on the sawmill, the conveyor may be a stationary carriage whilst the head rig moves through the log; or the head rig may be fixed whilst the log moves on a mobile conveyor.

9. Resawing Multiple blades reduce the large-cut cants to smaller sizes according to the required use.

15

Production of timber

Process 11. Sorting

10. Edging and trimming

The cut lumber is then sorted by lengths, species and dimensions into bins to then be placed onto palettes for easy transportation and storage.

Rough round edges are removed either by a circular saw or a chipper edger. This is to produce standardised widths and lengths, with edges squared and defects removed. This can be by one or more trimming saws.

vertical sorter

11

10

horizontal sorter

12

Log ladder and sawi

Final preparation

17

packaging & storage

planer transportation 17. Packing, storage and transportation The dried timber is sorted for final inspection of any defects that may have occurred during the drying process. These can be removed with trimming, before being packed and stored in warehousing, to then be transported for further processing of woodbased products.

16

Process 13. Sealing timber

12. Stacking The sawn and trimmed timber is sorted according to thickness, width, length, quality, grade and species, depending on market requirements. This can be done manually or by mechanised sorters.

air drying shed

To protect the sawn timber against fungi and insects, and to inhibit the tendency of airdried lumber to check and split, the ends may be brushed, dipped or sprayed in a suitably prepared chemical solution. This acts as a sealant in order to bring about a slower and more uniform drying process.

14. Air drying The sawn timber is stacked into piles out in the open or under sheds where they are exposed to good air flow.

13

ing

14 Seasoning

16

planer infeed

16. Planing Once the lumber has dried, it is taken to the planer infeed. This is where the timber is given final shaping and its smooth finish and appearance.

15

kiln drying shed

15. Kiln drying Alternatively, the sawn timber is stacked in a closed and controlled environment where temperature, air circulation and humidity is regulated so to achieve the most economical drying conditions without affecting the timber. Batch kilns dry the timber in chambers as a batch charge, whilst progressive kilns dry the timber as it passes through the kiln on trucks.

17

Production of timber

Process

Explaining the opportunities and projects

Key critical projects within the sawmill have been highlighted along the schematic to make it easy to identify which areas of the process have most opportunity.

sorted logs

log deck

scanner

4 Infeed, scanning and sorting

4. Sizing and sorting

Key product groups • Adapter sleeves • Bearings - flange bearings, housed bearings, spherical roller bearings, and split bearings • Belts - synchronous belts, timing belts, v-belts, and belt drives and pulleys • Blowers • Chain - conveyor chain, roller chain, chain sprockets, chain tensioners, and chain oil • Fans • Flexible claw • Flexible couplings • Grease • Hydraulics - silent blocks • Plain bushings • Plastic wrap • Pumps • Rod ends • Slewing rings • Sold steel units

Critical projects and opportunities • Replacement of rubber conveyor belt used in scanners. SOV: 10 - 15k€.

18

3. Infeed

Key product groups • Bearings - filament bearings, housed bearings, plummer Debarking block bearings, and spherical roller bearings • Adapter sleeves • Bellows • Chain - conveyor chain, roller chain, supporting profile, and chain oil

• • • • • • •

Chain sprockets Couplings Gear drives Grease Shaft-locking devices Swing drive Synchronous belts

Critical projects and opportunities • This part of the process in the sawmill is often over-loaded with high impact and vibration.

Overhung loading can affect the gear drives, chain and bearings.

• High durability is critical to handle shock and perform under load.

• Plummer block housings with reinforced designs are often used.

• Chains run dry, without lubrication, due to the amount of sawdust in the environment. Annual replacement of chain. SOV: 50 - 100k€.

Process

3

2

1

Collection of raw material

1. Felling

2. Transportation

Key product groups • Bearings - spherical roller bearings, and tapered roller bearings Log ladder and sawing • Belt drives • Grease • Hose, hose assemblies and adapters • Hydraulics

Key product groups • • • • • • •

O-rings Plain bushings Plastic wrap Seals Slewing rings Truck-mounted crane Turntables

Critical projects and opportunities • Individual cost per slewing ring. SOV: 15 - 20k€.

• Belts - synchronous belts, timing belts, and v-belts • Chain • Couplings

• Hose, hose assemblies and adapters • Plastic wrap • Saws • Sprockets

Critical projects and opportunities • High-wear environment, where chain needs to be replaced frequently.

• Harvester head supports the tree and de-limbs it.

The tree is then cut to length.

• Chain is used to pull on the tree with a special "U" attachment to get grip onto the tree and pull it through the knives for the cutting mechanism.

• Winches are sometimes used with chain and conveyor inside.

19

Production of timber

Process

Explaining the opportunities and projects

Key critical projects within the sawmill have been highlighted along the schematic to make it easy to identify which areas of the process have most opportunity.

5. Debarking

6. Waste conveyor

Key product groups • Bearings - cylindrical roller bearings, filament bearings, spherical roller bearings, split bearings, and housing units • Belts - synchronous belts, rubber conveyor belts, v-belts and belt drives • Conveyor chain

Key product groups • • • • • • • • • •

Couplings Fans Gear drives Grease Hydraulics Hose assemblies Power packs Pumps Saws Solid steel units

• Bearings - housed bearings, spherical roller bearings, and split bearings • Belts - synchronous belts, and v-belts • Chain - conveyor chain, leaf chain, roller chain, and chain oil

Gear motor Grease Hydraulic drives Power packs Shaft-locking devices Solid steel units

Critical projects and opportunities • Without proper maintenance, bearings in pelletizers Infeed, scanning andInstalling sorting can require replacement every 500 hours. high-performance spherical roller bearings can increase bearing life by five times, operate in cooler temperatures, and require less maintenance.

• Annual instalment of pan grinder rollers adjusted for taper roller bearings to improve service life by 3 times. SOV: 4k€ for two presses.

• Belts with metal rivets can be used by metal detectors to scan for debris.

• Waste can be transported for use elsewhere e.g., bioenergy, pulp, or can be even used in ovens to generate heat for dry installations.

Critical projects and opportunities • Some smaller debarkers use drive belts - in a very harsh environment where wood and bark pieces fly around, belts can be cut regularly with open drives.

• Link belting is sometimes used as an alternative as it is made from durable material that can withstand cuts from wood chips due to being pre-tensioned and the ability to replace individual links rather than the entire belt. Swap from drive belts to link belting - SOV: 1k€ cost-saving.

• Alternatively, rubber conveyor belts can be used in waste conveyors. SOV: 5k€.

5

6

7

edger debarker

waste conveyor

Debarking

20

• • • • • •

Process

9. Resawing

7. & 8. Headrig + breaking down

Key product groups

Key product groups

• Bearings - housed bearings and spherical roller bearings • Belts - synchronous belts and v-belts • Chain - conveyor chain and chain oil • Grease

• Bearings - housed bearings and spherical roller bearings • Belts - synchronous belts and v-belts

Critical projects and opportunities

Critical projects and opportunities

• Several options for headrig and primary breaking down: headrig, center line, band mill and vertical or horizontal gang edgers • Extended length belts (up to 20m long) are ideal for these types of environments, compared to the equivalent chain. Extended length beltsCollection are much of raw material lighter and energy-saving.

• There is a lot of dust in this part of the process, with heavy loads on all components.

8

• Conveyor chain and technology • Hydraulics

9 headsaw fixed saw

log ladder / carriage

Log ladder and sawing

21

Production of timber

Process

Explaining the opportunities and projects

Key critical projects within the sawmill have been highlighted along the schematic to make it easy to identify which areas of the process have most opportunity.

Log ladder and sawing

vertical sorter

10

10. Edging and trimming

11

horizontal sorter

12

Key product groups

Critical projects and opportunities

• • • • • • •

• V-belts on trimmers can wear very quickly due to significant dust and movement of blades.

• Some trimmers are connected via tubes, and take the sawdust to a container to go to paper plants. The sawdust must be clean, but sometimes rubber belts can elongate and break, causing pieces of rubber to mix with the sawdust.

Ball bearings Belts - synchronous belts and v-belts Gear motor Grease Hydraulic drives Shaft-locking devices Welded steel chain

11. Sorting

Key product groups • Adapter sleeves • Bearings - ACIS proof bearings, spherical roller bearings, split bearings, and housing units • Bellows • Belt - conveyor belts, synchronous belts, timing belts and pulleys, and v-belts

Critical projects and opportunities • Chain - conveyor chain, roller chain, and chain tensioners • Grease • Helical gearboxes • Locking elements • Pneumatics • Solid steel units • Split clutches

• Big rollers are hung up mid-air and driven by rubber v-belts (4 - 6 belts per roller). Each roller can weigh up to 60kg.

• Depending on the length of the line, swapping to link belting can save between 5 - 15k€ annually.

• Replacing banded belts with link belt. SOV: 25k€ cost saving.

• Replacement of rubber conveyor belt. SOV: 5k€.

• Classic v-belts can be hard to replace in this remote area of the production line, with severe health & safety risks due to the wetness and dust in the environment.

12. Stacking

Final preparation

Key product groups • Bearings - ball bearings and flange bearings • Gear motor • Grease

22

Critical projects and opportunities • • • •

Roller chain Shaft-locking devices Slewing rings V-belts

• Stacking systems also use rollers similar to those in the sorting process. These can be hard to replace due to the need to lift the rollers to re-install the belts.

Process

Seasoning

air drying shed

13

14

13. Sealing timber

14. & 15. Air + kiln drying

Key product groups

Key product groups

• Bearings - ball bearings and filament bearings • Gear motor • Shaft-locking devices

• Bearings - ball bearings and split bearings • Belts - synchronous belts and v-belts • Blowers

• Chain - leaf chain and roller chain • Couplings • Heaters • Pneumatics

Critical projects and opportunities

15

• Many sawmills make their own customised kiln designs.

• Link-belting is resistant to chemical and high heat exposure, meaning the belts can last for over 15 months without needing frequent service.

kiln drying shed

23

Production of timber Explaining the opportunities and projects

Process

Key critical projects within the sawmill have been highlighted along the schematic to make it easy to identify which areas of the process have most opportunity.

Log ladder and sawing

17. Packing, storage and transportation

17. Packing, storage and transportation

Key product groups

Critical projects and opportunities

• Bearings - ball bearings, flange bearings, spherical roller bearings, and tapered roller bearings • Belts - synchronous belts and v-belts • CAM followers • Chain - flyer chain, leaf chain, roller chain, and chain tensioners • Conveyor technology • Grease • Linear guidelines • O-rings • Pillow blocks • Plain bushings • Pneumatics • Seals • Shaft-locking devices • Slewing rings

• Belts with 14mm pitch have high strength, good environmental resistance and require minimal maintenance and lubrication.

• Replacement of all housed units to solid block housed units with seal encapsulation. This can extend the lifetime of the application by 20+ times, where previously the bearings would need to be replaced often due to the high wear in extreme conditions. SOV: 10k€.

• Using split couplings to reduce time invested, cost and production downtime. SOV: 10k€.

17

packaging & storage

planer transportation

24

Final preparation

Process

16. Planing

Key product groups • Bearings - ball bearings, spherical roller bearings, split bearings, and housing units • Bellows • Belts - synchronous belts and v-belts • Couplings - disc couplings and flexible couplings • Flexible claw • Linear guidelines

16

planer infeed

25

Production of timber Production and processing of timber – ‘Putting it all together’

4

3

2

Infeed, scanning and sorting

Collection of raw material

Debarking

5

6

Log ladder and sawing

7

8

9

Proportion of replacement products in the sawmill Belts

Couplings

Lubrication

Linear guide

6%

Bearings

4% 3% 30%

9%

9% Other - including seals, gears, and motors

14%

25%

Hydraulics and fluid power Chain

26

1

11

10

12

13 14

Log ladder and sawing

Seasoning

Final preparation

17

16

15

The approximate value of PT aftermarket sales in the European sawmill industry

300m euros 27

PART THREE

Using this document to develop business The following provides the reader of this document, either General Management or Sales Team, with some template questions to help generate revenue from this Production Line Intelligence overview and so develop business in the forestry industry.

For many of these questions you may already know the answers.

Others might be used on a regular basis when you visit customers and prospects in other industry sectors. It is meant as a resource to act as a prompt and reminder allowing your business to fully capitalise on this market intelligence and production information.

There are three parts that deal with: 1.

Preparing (before any visit takes place) – this provides questions to think about and address before attending the company’s site. This further breaks down into two sections being: a. Detail of the company itself b. The people to be seen and which department 2.

The meeting – questions to ask during the meeting to understand the needs, requirements, and potential sales opportunities in the prospective customer 3. The follow up – questions to ask or to reflect on, at the end of the meeting or afterwards

Preparing – before the visit The 'Extraction Site' or 'Sawmill'

The people to meet

•

What are you visiting?

•

Who are you going to see?

– An extraction site of raw materials with winching and sawing capabilities?

•

What is their role or speciality (production/maintenance manager/repair/purchasing)?

– Is this transported by road, rail, or water for processing at the sawmill?

•

What do you know about them already? (hint: search LinkedIn)

– A sawmill - from sorting, screening, debarking, planing and distribution?

•

What is your initial summary as to the main challenges they face in relation to purchasing the types of products you can supply?

•

What do you already know about: – The size and throughput?

General

– Its scale in terms of capacity, output etc?

•

– Whether the extraction site or sawmill is specific to a particular end market e.g., construction, furniture, wood-working, or pulp and paper?

28

What are your primary objectives for the meeting – what do you want to achieve?

– Exploratory – Presentation

– What type of tree do they typically have access to in the region and/or process e.g., pine, spruce or beech etc.

•

– Do the system suppliers provide after market warranty service?

What are the fall-back objectives if the primary objectives are unachievable?

•

What is your proposed agenda?

•

How old is the facility?

•

•

How many people do they employ?

What kind of questions will you ask (in relation specifically to who will be seen)?

•

Do they have in-house maintenance engineers?

•

•

Who decides on purchasing?

What is your plan for follow ups to this meeting (further meeting/proposal/meeting with other people)?

•

Does this company have other facilities in your region/territory?

•

What kind of support material do you need to take with you?

– Breadth of service

The actual meeting 'Extraction Site' or 'Sawmill' (If not already known, any of the preparation questions can be asked during the meeting to establish site type, size, capacity, age, as noted).

The facility

•

Do you have existing projects carried out in relation to maintenance or energy management etc?

– Are existing partners – suppliers or distributors – assisting?

•

What are the key maintenance/industrial supplies objectives for the facility?

•

What sort of plant or facility is this e.g., extraction of timber or processing of raw materials?

•

What are the processes used from receipt to dispatch?

The most utilised products

– Infeed, scanning and sorting

•

– Debarking

– What are the issues/challenges faced getting those parts?

– Log ladder and sawing – Seasoning

•

What are the main concerns in relation to type of production parts that are needed to maintain and improve the line e.g., bearings, chain, belts, etc?

•

Where is the process most prone to failure or maintenance problems?

– Final preparation - planing, packaging, storage and distribution •

How are the main machines maintained and repaired?

– Internal team, external team, machine builder service engineers?

Maintenance, planning and issues •

Suppliers •

What do you value most in relation to a supplier/ distributor like us?

•

What kind of support do you look for from your service providers in relation to on-going or emergency maintenance?

•

What is your biggest current problem with your parts suppliers?

What sort of regular maintenance does the plant undergo?

– Regular shut-down periods or other?

•

What is the estimated annual spend on maintenance?

•

What are the main issues in relation to maintenance?

•

What are the 'bottlenecks' in the process that affect speed or reliability?

– How do you like your supplier partners to assist?

– What are the main issues in relation to maintenance?

– What are they caused by?

What parts are used most on an annual basis?

•

What are the next steps?

– Can we come back with a proposal to help you with some of this?

– Are there on-going projects to deal with this?

– Are you using partners – suppliers or distributors – to assist you in this process?

The follow up •

What were the main points you learned from the visit?

•

How will you complete these?

•

How are you going to store this information?

•

What other types of follow up will you undertake and why?

•

How are you going to use this information?

•

Who in your business do you need to share this information with?

•

What are the next steps you need to take and when?

– What have been the success stories?

– How can these be replicated?

•

How will you ensure that these follow ups are completed?

29

Acknowledgements Acknowledgements and a sincere thank you to the following manufacturer members of EPTDA for the generosity of the technical and commercial information and advice that they have supplied and which has given real authority to the document.

Also to a number of technical experts from distributor members of EPTDA operating in this sector, who have provided the concrete examples included in the text and without whose contribution the document would lack its operational and commercial relevance and power for distributors.

Finally to the individual members of the EPTDA Know Your Market Committee and particularly to its Task Group, who have freely given their advice, guidance and inputs throughout the process of producing this document.

Authored by: Disclaimer: The costed examples contained in this document are illustrations taken from real practice. They are, however, not predictions of future value achievable from various projects that can be undertaken in this sector. The authors, contributors and EPTDA do not accept any liability for any commercial decisions that may be taken as a result of these examples.

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European Commission, ‘Communication from the Commission to the European Parliament, the council, the European Economic and Social Committee and the Committee of the Regions: A new EU forest strategy: for forests and the forest-based sector’ The Business Research Company, ‘Forestry and logging global market report 2021’ European Panel Federation, ‘EU forest-based industries 2050: A vision of sustainable choices for a climate-friendly future’ MarketResearch.com, ‘Forest products in Europe – Market summary, competitive analysis and forecast to 2024’ European Organisation of the Sawmill Industry (EOS), ‘EOS annual report 2019-2020’ Forestry Commission, ‘Forestry statistics 2020 – Chapter 9: International forestry’ Forest Europe, ‘State of Europe’s forests – 2020’ Euroaxess, ‘Labor market briefings series: The agriculture and forestry sector in Europe’ Ibid.

Forest Europe, ‘State of Europe’s forests – 2020’ The Sawmill Database, 'Sawmill list by country' Eurostat, ‘Forests, forestry and logging’ The Sawmill Database, 'Sawmill list by country' Forest Europe, ‘State of Europe’s forests – 2020’ European Panel Federation, ‘EU forest-based industries 2050: A vision of sustainable choices for a climate-friendly future’ Food and Agriculture Organization (FAO) of the United Nations, 'Employment trends and prospects in the European forest sector' Eurostat, ‘Forests, forestry and logging’ Forest Europe, ‘State of Europe’s forests – 2020’ Europa, ‘Pinus sylvestris in Europe: distribution, habitat, usage and threats’ Europa, ‘Picea abies in Europe: distribution, habitat, usage and threats’ Europa, ‘Fagus sylvatica in Europe: distribution, habitat, usage and threats’ The Business Research Company, ‘Forestry and Logging Global Market Report 2021’ Ibid.

JRC Publications Repository, ‘Chemical and material driven biorefineries in the EU and beyond’ Ibid.

Forestry Commission, ‘Forestry statistics 2020 – Chapter 9: International Forestry’ EOS, ‘Annual report 2019-2020’ European Panel Federation, ‘Forest-based industries 2050: a vision of sustainable choices in a climate-friendly future’ EOS, ‘Annual report 2019-2020’

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