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TA K I N G
STOCK
NOTHING LIKE GOING BACK
■ ■ ■ ■ ■ Hatton-Brown Publishers, Inc. Street Address: 225 Hanrick Street Montgomery, AL 36104-3317 Mailing Address: P.O. Box 2268 Montgomery, AL 36102-2268 Telephone: 334-834-1170 Fax 334-834-4525
■ ■ ■ ■ ■ Publisher David H. Ramsey Chief Operating Officer Dianne C. Sullivan
■ ■ ■ ■ ■ Editor-In-Chief Rich Donnell Senior Editor Dan Shell Senior Associate Editor David Abbott Senior Associate Editor Jessica Johnson Associate Editor Patrick Dunning
■ ■ ■ ■ ■ Publisher/Editor Emeritus David (DK) Knight
■ ■ ■ ■ ■ Production Manager/Art Director Cindy Segrest Ad Production Coordinator Patti Campbell Circulation Director Rhonda Thomas Online Content & Marketing Manager Jacqlyn Kirkland
■ ■ ■ ■ ■ Advertising Sales Manager David H. Ramsey • (334) 834-1170
■ ■ ■ ■ ■ ADVERTISING SALES REPRESENTATIVES SOUTHERN U.S. Kathy Sternenberg • (251) 928-4962 ksternenberg@bellsouth.net Classified Advertising Bridget DeVane • (334) 669-7837 • 1-800-669-5613 bdevane7@hotmail.com MIDWEST USA, EASTERN CANADA John Simmons Mar-Tech Communications 32 Foster Cres. Whitby, Ontario, Canada L1R 1W1 (905) 666-0258 Fax: (905) 666-0778 E-mail: jsimmons@idirect.com WESTERN USA, WESTERN CANADA Tim Shaddick 4056 West 10th Ave, Vancouver BC Canada V6L 1Z1 604-910-1826 Fax: (604) 264-1397 E-mail: tootall1@shaw.ca Kevin Cook (604) 619-1777 E-mail: lordkevincook@gmail.com INTERNATIONAL Murray Brett 58 Aldea de las Cuevas Buzon 60 03759 Benidoleig (Alicante), Spain Tel: +34 96 640 4165 +34 96 640 4048 E-mail: murray.brett@abasol.net
T
hrough the course of time, as we editors travel to wood products mills around the world, we begin to view some mills as more than just a mill, but rather as a member of our editorial family. Take this issue’s cover story for instance—the RoyOMartin southern pine plywood mill in Chopin, La. Panel World editors have visited this mill and written articles on it four times since it started running in 1996. I went there almost exactly 23 years ago, several months after it peeled its first block in February 1996. After considering the construction of a southern pine sawmill, Martco (Jonathan Martin and Jerry Buckner in particular) realized a plywood mill would better address its wood utilization situation. Martco officially announced the project in 1994 at a cost of $50 million and with a stated production capacity of 250MMSF (3⁄8 in.). It was very special to be able to visit with these gentlemen and tour the mill for the article. Martco had gone with Durand-Raute for most of the machinery, having come away impressed with some similar equipment it had seen in action at Plum Creek Timber’s plywood mills in Montana. The next time Panel World went back to Chopin was in 2007. Our senior editor Dan Shell made that journey, mainly because the mill had started up a second plywood line—heavier to USNR (Coe) and SparTek this time (including a seven ply foam glue layup line—and had increased annual production capacity to 470MMSF, going after smaller logs in longer lengths. It was my turn again in 2011, and while the mill had made some equipment improvements, boosting production to nearly 490MMSF, the brunt of the article was on the company’s Living With Wellness Program, which emphasized the idea that a healthier employee is also a safer worker. Looking back on it, I think I went back mainly because I just wanted to see how the
mill had evolved since my initial visit. A few things caught our attention for this latest visit for the article in this issue. The trip to the mill had brought in some dryers since our previous visit, and had recently undergone considerable upgrade to its automation systems and controls throughout the mill. Production had hiked again to 510MMSF, more than double the original output. But what really caught our eye was that a couple of years ago the mill had implemented a timbers sawmill line, utilizing the non-plywood stems from the optimized multi-saw bucking line. The editor who visited the mill and wrote the story in this issue, Jessica Johnson, was all of eight years old when I visited the new mill in 1996. Maybe now you can begin to see how a mill can traverse our editorial landscape. PW
RICH DONNELL EDITOR-IN-CHIEF
Ph: 334-834-1170 Fax: 334-834-4525 e-mail: rich@hattonbrown.com
PanelWorld • SEPTEMBER 2019 • 3
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(Founded as P l y w o o d & P a n e l in 1960—Our 498th consecutive issue) VOLUME 60 NO. 5
36
SEPTEMBER 2019
Visit our web site: www.panelworldmag.com
QUALITY CONTROL It Should Be Everywhere
46
CANADA TACKLES RESINS Cleaning Up Formaldehyde
TAKING STOCK Mills Come To Life
SUPPLY LINES Hexion On Track
PANELWORKS Classified Advertising
UPDATE Court Sides With U.S.
CLIPPINGS Personnel Movements
EVENTS Back Half Of 2019
3 6
PROJECTS Latest At Freres
30
54 64
GEO DIRECTORY Veneer Panel Suppliers
66
COVER: RoyOMartin continues to get more out of its giant softwood plywood mill at Chopin, La., including a timbers sawmill. Story begins on PAGE 14. (Jessica Johnson photo)
69 70
Panel World (ISSN 1048-826X) is published bimonthly by Plywood & Panel World, Inc., P.O. Box 2268, Montgomery, AL 36102-2268 (334) 834-1170, Fax (334) 834-4525. Subscription Information— PW is sent free to owners, operators, managers, purchasing agents, supervisors and foremen at veneer operations, plywood plants, composite products plants, structural and decorative panel mills, engineered wood products plants and allied export-import businesses throughout the world. All non-qualified U.S. subscriptions are $50 annually; $60 in Canada; $95 (Airmail) in all other countries (U.S. funds). Single copies, $5 each; special issues, $20 (U.S. funds). Subscription Inquiries—TOLL-FREE 800-6695613; Fax 888-611-4525. Go to www.panelworldmag.com and click on the subscribe button to subscribe or renew via the web. All advertisements for Panel World magazine are accepted and published by Plywood & Panel World, Inc. with the understanding that the advertiser and/or advertising agency are authorized to publish the entire contents and subject matter thereof. The advertiser and/or advertising agency will defend, indemnify and hold Plywood & Panel World, Inc. harmless from and against any loss, expenses, or other liability resulting from any claims or lawsuits for libel violations or right of privacy or publicity, plagiarism, copyright or trademark infringement and any other claims or lawsuits that may arise out of publication of such advertisement. Plywood & Panel World, Inc. neither endorses nor makes any representation or guarantee as to the quality of goods and services advertised in Panel World. Hatton-Brown Publishers, Inc. reserves the right to reject any advertisement which it deems inappropriate. Copyright ® 2019. All rights reserved. Reproduction in whole or in part without written permission is prohibited. Periodicals postage paid at Montgomery, Ala. and at additional mailing offices. Printed in USA.
Postmaster: Please send address changes to Panel World, P.O. Box 2419 Montgomery, AL 36102-2419. Member, Verified Audit Circulation Managed By Hatton-Brown Publishers, Inc.
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UPDATE
U.S. COURT SAYS CHINA AT FAULT
U.S. Court of International Trade in June upheld a U.S. International Trade Commission determination that the People’s Republic of China is injuring the U.S. hardwood plywood industry by exporting hardwood plywood supported by unfair subsidies and selling it at below market value (otherwise known as dumping) in the U.S. The decision stems from a petition filed by the Coalition for Fair Trade of Hardwood Plywood with the U.S. Dept. of Commerce and ITC in November 2016. In its preliminary determination, Commerce found that hardwood plywood from the PRC was being sold at less than fair value and that the PRC industry was receiving countervailable subsidies. Concurrent with Commerce’s proceedings, the ITC investigated whether the domestic industry was materially injured or threatened with material injury
Several U.S. hardwood plywood producers initiated the petition.
by the imports. ITC issued a preliminary determination find that there was reasonable indication of injury to the U.S. industry, and subsequently in a final determination concluded that the U.S. hardwood plywood industry is ma-
terially injured by the PRC imports because they’re subsidized and sold in the U.S. at less than fair value. The Coalition for Fair Trade of Hardwood Plywood includes Columbia Forest Products, Commonwealth Plywood,
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UPDATE
Murphy Company, Roseburg Forest Products, States Industries and Timber Products Co., all domestic producers of hardwood plywood. American Alliance for Hardwood Plywood and related companies subsequently challenged aspects of the ITC final determination of injury. These companies include Far East American, Inc., Northwest Hardwoods, American Pacific Plywood, Canusa Wood Products, Concannon Lumber and Plywood, Fabuwood Cabinetry Corp., Hardwoods Specialty Products, Holland Southwest International, Liberty Wood International, McCorry & Co., MJB Wood Group, Patrioit Tmber Products, Richmond International Forest Products, Taraca Pacific, USPly Trade Co. and Wood Brokerage International. A separate complaint against the ITC ruling was filed by Zhejiang Dehua TB Import & Export Co. and affiliated plaintiffs. The complaints against the ITC injury determination challenged the ITC’s findings that imports from PRC are substitutable with domestic hardwood plywood; that the volume of imports from PRC are significant; that imports from PRC undersold domestic hardwood plywood and resulted in price suppression; that imports from PRC significantly impacted the domestic industry. U.S. Court of International Trade denounced these challenges and upheld the ITC determination of injury. On the specific challenge as to the degree of volume of imports from PRC, the Court pointed to the ITC finding that between 2014 and 2016 the market share of imports from PRC increased from 37.9% to 40.1%, while the domestic industry decreased from 21% to 17.3%. And specifically in the cabenetry end use segment, hardwood plywood imports from China increased from 224MMSF to 301MMSF, increasing its market share by 6.9%, while the domestic market share decreased by 5.1%. The Court emphasized that ITC overall noted that the domestic industry’s production, capacity utilization, end-ofperiod inventories, shipments and market share all declined during the investigation period, as did net sales revenues, cost of goods sold, ratio of operating incomes to net sales, gross profit, operating income and net income.
TIMBER SITUATION CURTAILS OSB MILL Norbord Inc. announced its intention to indefinitely curtail production at its oriented strandboard (OSB) mill in 100 Mile House, British Columbia as of August. The Cariboo region in which the mill is located has been under mounting wood supply pressure for the past decade as a result of the mountain pine beetle epidemic. This challenge has been more recently exacerbated by the significant wildfires that the province of British Columbia experienced in the summers of both 2017 and 2018. The resulting wood supply shortage and high wood prices do not support the economic operation of the mill at this time, the company states. Norbord will continue to supply its current customers and meet expected future customer demand with production from its 11 other operating North American OSB mills, including High Level and Grande Prairie, Alberta. The 100 Mile House mill has a stated annual production capacity of 440MMSF (3⁄8 in. basis). Approximately 160 employees are impacted by this curtailment.
EPF ADDRESSES FORMALDEHYDE The European Union needs to harmonize the compulsory parameters for formaldehyde in panels, both to regulate the importation of products from elsewhere, and to avoid creating hurdles within the community itself, according to the European Panel Federation (EPF) and its chairman, Paolo Fantoni. “Currently, seven of the 28 EU countries have a mandatory limit on formaldehyde emissions,” Fantoni says. “Among these, Germany is considering introducing more restrictive rules and test methods unilaterally, but this would limit free competition within the single market. As a result, it would not only put European producers in difficulty, leaving the doors wide open for completely unregulated products to be imported from outside Europe, but it would also create confusion among European consumers. We therefore ask the new EU bodies to urgently adopt a harmonized directive on this matter.” Standard EN13986 divides formaldehyde emissions into two categories: E2
and E1. The second, lower emission rate (0.1 parts per million as recommended by the World Health Organization) was adopted by all EPF companies back in 2007. “Our proposal,” Fantoni specifies, “is to unify the rules throughout the EU, introducing a compulsory E1 limit, for both the production and the importation of panels and furniture. At the same time, we would also like to see the introduction of a further voluntary standard, set at 50% of the emission levels of E1, to which individual businesses can choose to adhere.” In 2018, European panel production came to 59.3 million m3, an increase of 1.7% on the previous year, but still showing a slow down, given that the increase in 2017 was 3.2%. In the first quarter of 2019, compared with the same period of 2018, indicators suggest a reversal in terms of production levels, which dropped by 1.2%, as a consequence of the uncertainties affecting industries in the downstream supply chains.
IKEA WILL CLOSE LONE U.S. PLANT IKEA Industry announced it will discontinue production at its Danville, Va. location in December. The plant, which has been in operation since 2008 and currently employs 300, produces woodbased furniture for IKEA retail stores in the U.S. and Canada. Production will be moving to existing IKEA manufacturing units in Europe to meet the demand for affordable furniture products in North America. “This was an extremely difficult decision to receive. We made every effort to improve and maintain the competitiveness of this plant, but unfortunately the right cost conditions are not in place to continue production in Danville for the long-term,” says Bert Eades, Site Manager, IKEA Industry Danville. The plant mainly produces KALLAX shelving units and BESTÅ living room storage units for IKEA U.S. and Canada. IKEA states the cost structure for production in Danville is too high, especially when it comes to raw material, resulting in pricing that is significantly higher than other IKEA Industry units making the same products in Europe.
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LOUISIANA BEHEMOTH: MARTCO CHOPIN KNOWS SOUTHERN PINE PLYWOOD The largest single site plywood facility in North America, Martco L.L.C. in Chopin, La. emphasizes safety and product versatility. BY JESSICA JOHNSON
CHOPIN, La. force in southern forest products for more than 95 years, the Martin family has done a little bit of everything. But there’s one line of business, aside from forest management, that has outlasted them all—southern pine plywood. Martco’s plywood plant in Chopin, which was first brought on-line in February 1996, isn’t just big. And it isn’t just safe. The Chopin facility is the largest operating SYP plywood facility in the world, thanks to its monster production of 510MMSF on a 3/8 in. basis in 2018. And the Chopin team was just recognized by APA—The Engineered Wood Assn. with the “Annual Safety and Health Honor Roll 2018, First Place, Division 1-Plywood” as the safest plywood plant in North America for a record-breaking seventh time. The company also recently recognized its Chopin plywood finishing and shipping departments for six years of no OSHA recordables. And since we’re on the subject of “safe,” the company’s land and timber departments have completed 12 years of no recordables.
A
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Technical Manager Robert Willett says the team works hard every day to ensure not only that Chopin is producing superior products, but that it does so safely—a huge point of pride for Martco. “It’s not just something we say. We live it. Our entire management team
here lives it, and I know upper management lives it as well,” he emphasizes. Of course, the culture of Chopin matches that of the rest of the organization, with implemented programs such as “I Believe in Zero” injuries and the “5 STEPS to Zero” incidents in ➤ 18
Since startup in 1996, Chopin has been expanded into two lathe lines and three presses.
Martco’s Chopin pine plywood mill produces 510MMSF annually.
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Ensuring safety of employees is a critical aspect of the monster-sized plant, with banners touting the company’s "5 STEPS to Zero" and “I Believe in Zero” safety programs.
15➤ place, as well as banners dotting the production areas with pictures of employees’ families to remind them the reason they work safe. Willett explains that 5 STEPS to Zero encourages all members of the plant before working during an upset condition to Stop what they are doing; Think about what they are going
to do; Examine how they are going to do it; Pursue any help if needed; and Start the process safely. Keeping a plant of Chopin’s size with an average of more than 100 days without incident is impressive. Willett says it means a lot to the facility to know that others have noticed their
dedication to keeping things running smoothly and safely. Chopin’s safety record is perhaps only slightly more notable than its production rate: In 2018 the facility turned over 510MMSF of pine plywood panels, a number that Willett says the facility should exceed in 2019 if everything goes according to projections. When you add the production coming off the Martco timbers mill of 26 million board feet of SYP kiln dried lumber, which shares inventory and merchandizing breakdown with Chopin’s plywood facility, the facility really is a behemoth. The Chopin mill has undergone extensive upgrades to its scanning software and hardware, and automation systems including PLCs and drives.
MILL FLOW With the addition of the timbers mill, the wood yard in Chopin processes logs slightly differently than some other plywood mills. All treelength material is lifted onto the stem deck with a LeTourneau pedestal crane and debarked using a Nicholson A8 debarker. Once scanned for optimum cut, logs are broken down into either 8 or 10 ft. blocks on a new PSI merchandizer. Blocks larger than 9.5 in. are processed strictly for plywood, and the remaining sawlog stem goes to the timbers mill. (See story, page 20) Waste wood is broken down with a Bruks chipper. From the merchandizer, blocks are put into one of six hot water conditioning vats. Blocks spend between six and 12 hours in the vats, Willett says, with a target core temperature of 130°. ➤ 24 18 • SEPTEMBER 2019 • PanelWorld
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MARTCO FINDS ITS TIMBERS
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hings are done a little differently at the Martco L.L.C. pine plywood plant in Chopin, La. Instead of just processing cores coming off the lathe for various markets, Martco went about three steps further. In October 2014, the company added a full-blown timbers sawmill, complete with dry kilns, making 26MMBF of southern yellow pine (SYP) timbers operating at the same 24/7/365 rate as the plywood plant. Products are marketed under the RoyOMartin brand name. The Martin family of companies is no stranger to the sawmill business, so when President, CEO, and CFO Roy O. Martin III and other executives noticed that a vast amount of canter wood was being shipped off to area paper mills,
they recognized an opportunity to maximize yield on the existing (and underutilized) merchandizer. The decision was bolstered by their forestry team’s ability to meet the needs of the expansion with second thinnings from both fee and vendor sourcing, and an available market for some key timber sizes. The company went to work making plans. By using the bigger ends off the butt cut to make plywood, the rest now makes timbers, creating essentially the perfect middle piece: Now Martco operates a timbers mill, with a planer mill, for material of the “middle” size. Timber Mill Manager Rob Blankenship says that while every day offers its own opportunities to improve, the mill is a perfect fit for the facility and the mate-
The 26MMBF pine timbers mill was added to the Chopin plywood site in 2014.
rial that is processed. A seasoned sawmill guy, having joined Martco’s former LeMoyen, La. pine and hardwood sawmill in 1983, Blankenship has been with the Chopin timbers mill since March 2014 and was part of its single shift startup in October 2014. He started with about 12 people working days only, seven days a week, 52 weeks per year. Blankenship’s team has worked so well, that the single day shift gradually increased to two shifts, and now operates four shifts, giving the timbers mill the same schedule the plywood plant has.
TIMBERS MILL FLOW Logs are loaded onto the stem deck with a LeTourneau pedestal crane and are debarked with a Nicholson A8 debarker. Once scanned for optimum cut, logs are broken down into either 8 or 10 ft. blocks on the new PSI merchandizer. Blocks larger than 9.5 in. are processed strictly for plywood. Any waste wood is broken down with a Bruks wastewood chipper. At the canter, optimization makes cutting decisions of either 5x5, 6x6 or 4x4. Cants travel to an Inotech tray sorter, which sorts by both width and length, then to the green stacker. At the green stacker, cants are dried either in the package kiln using hot oil or the brand new American Wood Dryers gas-fired track dry kiln installed in early 2019. Blankenship states the performance of the new American Wood Dryers kiln has reduced drying time by half. Timbers are dried to 19% moisture content and are then cooled for 24 hours before planing. Inotech provided a near complete solution in the planer mill, with the exception of the strapper, which is a Signode machine. Most products are planed S4S, though Blankenship says he does run rough products, mainly 5x5s, every so often. All products are graded to Timber Products Inspection standards, #1, #2 and industrial mostly for the Texas market, though some is shipped to Arkansas and the Midwest. Chopin’s timbers mill has another area of maximization that is slightly different than others—the mill has the ability to cut boards off the Inotech planer. Blankenship explains the planer has both a horizontal and vertical saw, and it will take a 5x5 and cut a 1x4
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Merchandizing line produces ply logs and sawlogs.
board off the top and side creating a 4x4. “This is just another way we’re able to maximize recovery with this mill,” he adds. “Before this planer, those diameter logs, the 5x5s, were making 4x4s. And the 1x4 would have been in the chipper.” The original Weinig planer is used for the boards coming off the Inotech planer. The timbers mill uses two Hyundai forklifts and one Hyster lift to move products throughout the grounds. Every Thursday the twoman maintenance team takes over to perform a range of PM checklist items to keep the mill running as smooth as possible. The same “5 STEPS to Zero” incidents safety protocol, a complement to the corporate-wide “I Believe in Zero” safety culture, is practiced in the timbers mill, and results prove it works: In its five years of operation, the timbers mill has
Timber Mill Manager Rob Blankenship
had only one recordable injury. Blankenship credits his whole 30person team with the quality and production continually getting better year over year. “It’s not just me or a couple of other people,” he reiterates. “It’s a team of dedicated employees striving to PW be better each day.”
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Nearly 50% of production is sanded siding.
Technical Manager Robert Willett
18 ➤ Two infeeds feed the two lathes, one a Raute lathe installed at startup in 1996, and a USNR lathe installed in 2007. Both lathe lines use Raute clippers and Ventek diverters. After peeling, sheets are sorted by moisture. Willett says the team has proven that sorting sheets by moisture creates cleaner stacks by allowing sheets to land better. Sheets are dried in one of five dryers: Two provided by USNR are six deck dryers, with 18 hot sections; one provided by Raute is a four deck dryer with 19 hot sections. The other two are USNR four deck dryers with one having 20 hot sections and the other having 18 hot sections. When Chopin expanded in 2007 with a second lathe line, the dryer capacity had to also expand. By choosing the 20 hot section dryer with the 18 hot section dryer from USNR, the facility is able to get what amounts to another dryer in the same amount of space as two dryers. After drying, pieces run through Ventek graders. The facility uses two Raute 14 bin stackers, one Coe 14 bin stacker and two Ventek strip stackers. The layup line was provided by SparTek—which includes a SparTek double five ply line, using Hexion glue, and a seven-ply foam line. Panels are pressed in one of three 50-opening presses, two by Raute that have been modified from their original form and one by SparTek. From the press, panels are put onto the Globe saw line after passing a GreCon thickness detector and a GreCon blow detector. Anything that needs patching is kicked to one of two patch lines. Panels are sanded on either the six-head Kimwood sander (which mainly han- ➤ 27 24 • SEPTEMBER 2019 • PanelWorld
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siding. All products are marketed under the RoyOMartin brand name.
MAINTENANCE One of the challenges of keeping a mill this size running is maintenance, Willett says, and thanks to the dedicated work of Maintenance Manager Nicky McNeely and his 90-person staff, things are handled efficiently. McNeely credits upper management for their support in making sure his team has the right spare parts when they need it. “We try to buy the best equipment out there and we try to maintain it as Recognized for the seventh year in a row by APA with the “Annual Safety and Health Honor world-class,: McNeely says. “The folks we work for believe in having Roll 2018, First Place, Division 1—Plywood” award, Chopin management and staff received spare parts and having the right the award from APA Director of Quality Services Steve Zylkowski. spare parts. That helps us out a lot.” 24 ➤ dles AC grade products) or the Annually, the mill goes down cold tators (ESP), one provided by Wellons for five to seven days for major installs, two-head Kimwood sander (which feeds and one provided by PPC Air. repairs and inspections. Not a set schedthe specialty saw for tongue and groove Willett muses that the plant pretty ule, Willett says these are planned products). Finished panels are strapped much makes everything—almost all sizes strategically looking at conditions, using a Samuel strapper and labeled with of AC and AB plywood from ¼ in. AC availability of equipment, and persona Samuel inkjet printer. all the way to 11⁄8 in. tongue and groove; nel. PM checklists are performed daily, furniture panels; rated sheathing; and Chopin is permitted currently as it has weekly and monthly depending on the heavy sanded siding. But he estimates been since startup in 1996. Therefore, the PW piece of equipment. that nearly 50% of production is sanded facility uses two dry electrostatic precipi-
PanelWorld • SEPTEMBER 2019 • 27
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PROJECTS CUSTOM BANDMILL FOR MPP
reres Lumber is investing in the next phase of its Mass Plywood F Panel (MPP) facility in Lyons, Ore.
with a brand new custom-built bandmill and carriage that will help the company produce MPP beams and timbers up to 24 in. by 24 in. This new equipment is a custombuilt solution created by USNR of Woodland, Wash. and Corvallis Tool Company (CTC) of Corvallis, Ore. USNR is producing a heavy-duty headrig bandmill and carriage. The order includes a 5 ft. high-speed double-column bandmill with a 10-knee carriage that is 60 ft. in length. The carriage offers highly accurate processing with soft dogs to securely hold the Mass Plywood Panel product. The carriage typically holds a log and travels past a bandmill to slab off pieces. In Freres’ unique circumstance, instead of holding a log the carriage will be holding a piece of MPP. While this bandmill is relatively standard, the carriage is going to be the longest USNR has ever produced at 60 ft. in length and has numerous modifications to account for the milling of a rectangular, engineered wood versus a green log. CTC, a company local to Freres Lumber, provides custom design-build manufacturing solutions. Freres knew they would be a natural fit for this one-of-akind project. CTC is supplying the hoists, transfers, edge easing, Precision End Trim saw, stacking and wrapping equipment. Throughout the entire manu-
Kyle Freres is feeling good about Mass Plywood Panel.
facturing process, it is paramount that no corner damage, scuffs or visible blemishes happen as a result of handling the material. This requires more refined mechanical methods in material handling. One of the unique challenges that this project presents is the sheer size of MPP that needs to be handled. In handling this large material, it is required to turn the product both 90 degrees as well as 180 degrees. A vertical bandmill is the right solution due to the 2 ft. maximum depth of cut required; a 60 ft. long carriage is needed to move the MPP through the vertical bandmill as the primary breakdown method. The newly designed system will provide flexible positioning that allows for tapered sawing or
straight sawing, giving Freres a high degree of cutting flexibility and highly accurate thin-kerf sawing to preserve yield. While the sheer size of MPP has posed its challenges in this project, it has boosted the enthusiasm as it provides a new challenge to these creative companies. Freres appreciates working with USNR and CTC on this collaborative, groundbreaking manufacturing project that will expand the uses for MPP. The Freres MPP plant started up in December 2017. Company officials felt they could leverage their veneer production expertise, and specifically produce a mass timber product using less wood than typical lumber-based crosslaminated timber.
STARWOOD STARTS UP P’BOARD PLANT On July 9 at 6:51 p.m., Starwood Orman Ürünleri Sanayi A.S. produced the first board on its new particleboard line in Negöl, Turkey. The line replaces a Dieffenbacher line commissioned in 1991. “Each first board ceremony feels like being the parent of a new baby,” comments Starwood CEO Hüseyin Yildiz. “The mother giving birth faces concerns, pain and some challenges, while the father has his own concerns and curiosity. Each child’s birth and each
New Dieffenbacher particleboard plant at Starwood in Negöl, Turkey.
Starwood CEO Hüseyin Yildiz pushes the start button for the new line.
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line’s ‘delivery’ are more exciting and more beautiful than the previous ones.” Yildiz says the project in Negöl was a real challenge from day one. “Together with the Dieffenbacher team, though, we have pushed the limits in terms of
delivery, timing and other aspects. We have gone beyond my expectations. Starwood learned a lot in the process, and the newest lesson was the power of teamwork with Dieffenbacher.” Most importantly, he adds, there
were no accidents. “We enjoy cooperating with companies and people who listen, who work hard to understand the needs of their customers and who have similar values,” Yildiz adds.
GP LAYS IT ON THE LINE
Georgia-Pacific’s OSB mill in Clarendon, SC, which was featured in the July issue of Panel World, invested in and is now running a new lamination line to lay its Thermostat radiant barrier for roof sheathing and ForceField air and water barrier for wall sheathing— a weather barrier overlay that on the job is installed with seam tape. It’s promoted as a faster installation and a more effective air barrier compared to traditional sheathing and house wrap. The new lamination line includes a GP unstacker and roll case infeed to the laminator, a Walco roll coat laminator, Raute outfeed conveyor, Con-Vey double stacker, Samuel stencil machine and Itipack strapper.
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EDITOR’S NOTE: These companies provided the following editorial articles and photos. Look for their advertisements throughout this issue of Panel World.
AIRSTAR The challenge was to develop a reliable quality control system that would test used, in-service scaffold planks for the construction industry. These planks are often utilized on high rise building scaffolding, thus the trust in safety of these structures is of utmost importance. The type of products tested include horizontally laminated scaffold planks, vertically laminated scaffold Airstar offers ultrasonic non-contact scan- planks, solid timber ner for scaffolding planks. scaffold planks and LVL formwork bearers. These products have a very rough, in-field service life cycle, resulting in a variety of damage-causing issues, most importantly traditionally undetectable structural damage, but also surface conditions—contaminations by concrete patches, films of paint etc. Also very common, after years of service, these planks contain rot and delaminations. Traditionally these scaffolds are repetitively tested by primitive mechanical stress load tests, often exceeding double the maximum service load capacity. Understandably, these tests add to the unseen internal structural damage of these planks. Airstar’s intent is that its revolutionary quality control method will completely replace the damaging mechanical load tests, ensuring safety to workers throughout the construction industry. Technically, the ultrasonic scaffold scanner is a version of Airstar’s well proven, high-performance Super Blow Detector, capable of penetrating all surface conditions and internal makeup of these varied scaffold planks. The scanner is fully adjustable to handle a variety of plank widths, thicknesses and material compositions. Importantly, the scanner provides continuously repeatable results, is very low maintenance, and can be operated by a single worker through its ease of use, defect marking and defect alarm light. This new revolutionary method’s effectiveness has been verified through factory comparative tests, through matching results of non-destructive ultrasonic tests vs. the destructive load tests.
ARGOS SOLUTIONS Automatic grading/inspection technology has evolved tremendously in the last 10 years with faster processors, bigger computer memory, better software development tools, and faster camera technology. Lead producers understand that automatic grading technology is not a luxury, but a must!
Argos Solutions has been one of the pioneers developing reliable visual inspection systems for the wood panel industry. The first systems were successfully installed behind particleboard and MDF sanding lines more Panel and furniture inspection by Argos than 20 years ago. After installing more than 300 systems in more than 30 countries, Argos Solution understands the key elements that panel and furniture producers need to provide a successful and reliable quality control system ensuring 100% inspection of surfaces and edge defects. Argos Solution has developed a method to capture images in a way that allow for normal vibration found on a belt conveyor or roller conveyor. There’s no need to install an expensive vacuum conveyor with more parts to maintain. The Argos system also provides an advantage with a thin and compact design that can be installed quickly and reliably on an existing line using only 2 ft. of space on existing conveyors with a minimum of 900 mm of clearance, eliminating the need to dig in the concrete on an existing low conveyor. Dust and vibration are the reality of every manufacturing environment, and being able to measure accurately in those conditions is what Argos Solutions has developed. The selfcleaning system eliminates the need for operators to stop production for cleaning the light source or camera when dust accumulation reduces the light level. Add the automatic calibration, and you have a very user-friendly system easy to operate and maintain. Another important part of quality control equipment is to support the process improvement effort by providing trustworthy and real-time information to operators for them to take action and improve the overall process. The Argos reporting module helps you track quality performance by product, shift, or any period that is needed. Coupled with the Real-Time Performance module, the system provides a key dashboard showing your quality performance. Pareto charts of your defects can display your Overall Equipment Efficiency (OEE) by combining the quality, speed and uptime performance measured by the AGS. In recent years Argos has developed a new generation of Argos grading systems tailor-made for laminated and decorative surfaces. The system uses multiple solid-state light sources in combination with ultra-fast camera technology that capture synchronized images that highlight the various surface defects in different decors and surface structures. The Argos image processing software uses a new concept of pattern matching and automatic recognition of product types to grade decorative panels. It can find the differences that are related to quality issues as well as new methods to reduce the risk of being falsely impacted by the vibration and the dust/debris that exists in an industrial environment. The AGS is built with many automatic features like automatic production change,
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automatic calibration, and self-cleaning feature to make it a stand-alone machine easy to use and maintain. The system also offers EiR technology for accurate measurement of the alignment between the press plate and décor paper. Every system is specifically designed depending on which type of product to grade with both hardware and software components. The system does not need training of defects; it has a built-in algorithm that only needs to be tuned for defect size and sensitivity. This allows for a quick startup because the different systems come with a predefined setup designed to differentiate between all these different types of defects to provide accurate and useful information to improve the overall quality performance. Argos was the first company to develop an Automatic Panel Repair system using the information from the AGS. The first system was installed in 2011 with Europe’s largest plywood manufacturer UPM. The success of the installation has been followed by two more installations within the same UPM Pellos factory. The high-pressure injection putty tool developed by Argos offer a much better repair than manual repair reducing fall-outs after sanding. Argos works with leading material handling companies like Biele and Con-Vey for turnkey projects.
CMC TEXPAN “Strategic quality management practices require a global approach and the wood-based panel industry makes no exception to that rule. Top-flight wood composites can CMC TEXPAN implements holistic approach be attained only to quality management. if each and every step of the production process is focused on quality,” comments Paolo Gattesco, Chairman of the Board of Directors at CMC TEXPAN, Italian subsidiary of the Siempelkamp Group. Needless to say, processing raw material plays a crucial role in all this. CMC TEXPAN machines are designed bearing in mind efficiency and linearity among their main targets, to maintain a high standard of quality throughout time, and they are manufactured in compliance with very strict mechanical requirements, to achieve a very precise selection and preparation of wood chips and particles. “Adjustability is another significant advantage of our machines,” continues Gattesco “The settings of the machinery can be changed very quickly to ensure an immediate reaction to any possible variations in the parameters of the material, thus minimizing waste.” CMC TEXPAN’s product portfolio also includes a whole range of equipment and devices, such as weighing scales, sensors and electronic systems, which measure and control the moisture and density of the particles or fibers being processed, thus enabling the operators to undertake inline corrections of
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the production parameters if necessary. “Our most recent development is a machine learning-based system, which has gone through a preliminary study and is now in the experimental stage,” informs Gattesco. “It is meant to be integrated into production: its function is to collect and process data obtained from the different machines. In this way, the system can identify potential problems before they actually occur and implement adequate corrective actions, so as to make sure that the features of the product remain constant throughout the whole production batch.” The system results in an improvement of quality, as well as in an economic saving. It offers an attractive option for the optimization of existing facilities, at the same time providing tremendous support for the staff assigned to the operation of the plant.
COIL MFG. Coil Mfg. precision spinning disc atomizers, rotary drum blenders and ancillary equipment maximize developments in resin blending technology and are employed for a wide range of resin types. The systems can also be modified or Coil installation at new SE OSB facility customized for specific features like dual resin input ports, quick disconnects, inverted cones and other features. In terms of cost, atomizers and blenders represent a fraction of an engineered wood panel operation. In terms of importance, this equipment is crucial to the quality and strength of finished products. Once waste wood has been chipped or wafered and dried, the atomizers and blenders represent the first crucial phase in the development of OSB products, particleboard and parallel strand board. If manufacturers don’t get it right at this stage, they won’t get a handle on quality control. That’s why every OSB company in North America, and almost every OSB firm worldwide, relies on Coil Manufacturing Ltd. After an installation is completed management from Coil will personally travel anywhere in the world to review the plant setup and offer startup assistance. With lower maintenance costs and less downtime, Coil Mfg. atomizers represent the heart of the system. Centrifugal atomizing, which runs on the spinning disc principle, does not require any maintenance or downtime for cleaning nozzles, or replacing plugged lines or filters. Every Coil atomizer system enables the operator to check each unit for speed (rpm’s) and temperature. The results are displayed on a user interface screen and can be integrated into the plant’s operating system. The interface screen also allows for finite adjustments to ensure optimal operating efficiency, and the precise amount and desired frequency of resin distribution. PanelWorld • SEPTEMBER 2019 • 37
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DIEFFENBACHER
Dieffenbacher’s holistic approach to quality control over the entire production process of woodbased panels is designed to achieve the best possible board properties. The best available quality control and measurement technologies from well-known manufacDieffenbacher forming station turers are intelligently linked and integrated into the Dieffenbacher control system. One example is the Dieffenbacher moisture measurement system. Its mechanical integration in the dosing bin of the forming station ensures a perfect and steady contact between the measurement head and the moving process material. Measuring the moisture of the material so close to the front of the dosing point leads to excellent accuracy of the bone-dry-based weight per unit area. Because the moisture measurement system is an integrative part of the forming station control system, previously complicated actions such as recipe changes and new calibrations of the device now require just one further click in the overall HMI (human machine interface) system. The new resin meter, which helps to increase glue quality and save resin costs, is another example. It precisely measures the water content in the glue mix, and has two applications. First, online monitoring at glue delivery—with detailed protocols for each truckload—can be used to detect unacceptable variations of resin content in the glue and justify warranty claims. Second, glue dosing can be controlled according to the actual resin content, which is continuously updated. This evens out variations in storage and delivery. Dieffenbacher’s fully integrated thickness measurement system is an integrative part of the Dieffenbacher press controller (DPC). The press distance control system and the board thickness measurement system are both combined in one common PLC system. This system influences the press distance, and the resulting thickness of the board is measured by the same system. Therefore, it is easy to make a precise correlation between a certain piece of board and the specific hydraulic cylinder settings. As a result, the control loop is much closer to the process and the board thickness can be automatically adjusted with unprecedented precision.
ELECTRONIC WOOD SYSTEMS Electronic Wood Systems of Germany (EWS) offers a complete range of inline and laboratory quality inspection systems for the panel board industry. The measuring tasks in this industry are versatile and challenging and reliable quality controls is a key factor for Industry 4.0 and automation. EWS has developed a density profile analyzer especially for light wood fiber materials for insulation panels with very low density of 50 to 350 kg/m² [3 to 22 lbs./ft³]. Measuring speed is 0.03 to 1.0 mm/s [0.001 to 0.04
EWS laboratory density profile analyzer DENSE-LAB X light
in.]. Resolution is +/-1% of measuring value. The development is based on EWS’s core feature of the MultiEnergy Technology, which enables variable measuring parameters. The basic model of the DENSE-LAB X system has been proven through 100 installations in MDF and particleboard production. The new model “DENSE-LAB light” is especially designed for the growing insulation board production. The system attracted high attention at this year’s Ligna and several systems are in operation already.
GRENZEBACH Moisture and thickness detection of veneers provides a great boost to quality and energy management in wood processing companies. Grenzebach presented its new, integrated moisture and thickness detection system for wood veneers, VILmt, at the recent Ligna show and attracted Grenzebach VIL-mt veneer inspection tremendous interest. The system can measure the moisture content and thickness of wood veneers separately or at the same time. It’s preferably used upstream and downstream from the dryer to allow optimum control of the energy input. It is possible to both show trends over a time period and create a mapping across different veneer species. The non-contact measuring system can also be used directly after veneer peeling because even very high moisture levels of 60 to more than 140% are handled with great accuracy. At the same time the veneer thickness can be determined continuously so that a control of the peeling line is supported. “Our system is ideal for the green peeling line end of the production line. In addition to the moisture content of a veneer sheet, its thickness can be continuously determined as well. This supports the control of the peeling line, giving the Grenzebach system a clear edge over other systems,” explains Dr. Christoph Habighorst, vice president Sales Building Materials Technology at Grenzebach BSH. ➤ 42
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A special technique optimizes the stability of the 40 ➤ readings, taking into account varying gaps between the sheets and the waviness of the veneers. The innovative system comes with all functions implemented for the major wood species such as beech, birch, oak or poplar. A configuration for others is possible upon request. Advantages include: —Moisture and thickness can be detected individually or at the same time, either in the form of a mapping or by a trend over time —Handles moisture levels of more than 140% —Contactless detection with good measurement accuracy —Flexible, modular software setup —Handles all wood species and veneers from 0.3 mm to about 4 mm thickness —Moisture and thickness detection combined in one system
IMAL-PAL GROUP IMAL-PAL Group offers a complete range of on line and laboratory quality control equipment: ● DYNASTEAM: application mounted at the infeed to the continuous press for the production of OSB, MDF and PB. Steam is injected into the top and bottom of the mat making it possible to increase production by as much as 30%. Other benefits of the installation include optimized density profile, less
porous surface, lower formaldehyde emission and a reduction in resin consumption. Over 107 systems have been installed on Imal-Pal, Siempelkamp, Dieffenbacher and Kusters press lines. ● FBC200 (Full Blister Control detector): current technol- IMAL-PAL full blister control detection ogy utilizes a limited number of control channels to detect panel delamination, where you may have, for example, 20 sensors controlling a 2500 mm wide board, but which can barely monitor 20% of the board because each sensor is only able to cover 25 mm, and i.e. 500 mm of the board. This newly designed system on the other hand is able to control the whole width of the board. ● A new lite version of this system is now available, the LBC100 (Lite Blister Classifier). Although the system does not have as many sensors as the FBC system, its coverage is nevertheless three times greater than the standard channel system. The LBC system may also be supplied in combination with the Imal Winthick gauge on the same beam.
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● Controlling the density profile is essential for MDF quality. The CDP700 analyzer is rapid, extremely accurate and able to analyze boards over a thickness range of between 3 mm and 60 mm. The CDP700 mounts both sensors below the board, a technical solution that protects the sensors from the vapors released by the board, hence they last longer and performance is not affected. ● The PSD400 (Press Security Device) is designed to protect continuous presses from foreign objects (pebbles, wire, resin chunks, plastic lumps, etc.) and other dense objects that could damage the belt—particularly important when producing thin panels. The X-ray system provides full mat width coverage and mat density is accurately displayed in 3D. ● ISO30X (On-Line X-ray mat density gauge) performs an accurate on-line weight per surface unit analysis and is an essential device for managing and controlling mat formation. ● MMW (Millimetric Waves Mat scan) system for controlling mat weight distribution online as well as moisture content, thickness and board weight after the press. Extremely accurate, rapid and safe scanning process without the application of X-rays or radioactive sources. ● WinThick (thickness gauging) highly accurate and reliable system for installation at press outfeed and sanding line with excellent all-round performance. Three-year warranty on the IMAL measuring sensors. The IMAL-PAL group also manufactures a full range of
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laboratory equipment such as the IB700 board property tester, DPX density profile meter, Lab Formaldehyde Tester, Fibercam and Screencam, for analyzing the granulometry of wood particles and fiber.
LIMAB
Since its start 30 plus years ago, LIMAB has been dedicated to the supply of quality control systems for highly accurate inline measurement of wood-based panels. We supply the major panel producers worldwide. With our PanelProfiler thickness measurement system you can improve your product quality and process efficiency. Continuous, high speed measurement in many panel positions, instead of limited manual sample tolerance checkings, greatly reduces the risk of producing out-of-tolerance panels. Reduced waste and happy customers help increase your profits. The non-contact laser measurement principle gives trouble-free operation for all types of panel of any thickness in all LIMAB PanelProfiler measurement
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production environments. No moving parts and no mechanical measurement wheels pressing against the panels, possibly giving scratch and dirt marks, gives a trouble-free operation with low maintenance costs. All PanelProfiler system versions have both temperature and mechanically stable measurement frames, which means that calibrations can be done with long time intervals, instead of between all panels, as is needed with the mechanical contact roller systems. Powerful fans and protection boxes around sensors are standard, eliminating the need for cleaning even in the toughest environments, like after presses. The system software is powerful, yet user friendly. Measurements are displayed in real time, graphically and numerically; out-of-tolerance alarms are activated as soon as something goes wrong. You can easily create product recipes, store measurement results for all panels and get production reports. Remote system diagnosis is standard. We can also supply customer designed level 2 communication solutions for various plant control equipment.
“Projects with annual plants are currently receiving the strongest response. We are seeing many projects from customers represented worldwide,” says Dr. Michael Schoeler, head of the Krefeld trial center. The further development of classic wood-based panels is also meeting great response in the market and even more demand from the Siempelkamp test center. Another project is dedicated to the production of hybrid boards. These new processes are characterized by a board surface that is particularly easy to coat and has very good mechanical properties.
WEMHÖNER
SIEMPELKAMP
Siempelkamp research and development center in Germany
Whether ContiRoll Generation 9 NEO, annual plants or new woodbased panelboard concepts, the future of the engineered wood industry is taking place at the Siempelkamp Research and Development Center in Krefeld, Germany. Customers worldwide are using one of the largest test centers in the industry for ambitious projects
more actively than ever before. Not only is the latest generation of the ContiRoll being tested here, the test center is also setting new benchmarks in numerous other research fields in close collaboration with woodbased panel producers. The ContiRoll Generation 9 NEO is “ready for take-off” in the Krefeld test center. Thus one of the most innovative press concepts enters the most important phase. The key features of this continuous press compared to its predecessor generations include: extended flexible press infeed, innovative heating concept, innovative hydraulics, increased press speed—features that have already motivated customers to buy the Generation 9 NEO. Resource efficiency and the use of annual plants in panelboard production are also among the current core topics of the Krefeld experts. Siempelkamp is positioning itself worldwide as a technological driver in this field. After intensive research and development, Siempelkamp brought new methods for processing alternative raw materials such as rice straw and bamboo for fiberboard production to series maturity. Following the first order from California-based CalAg LCC, which ordered a complete Siempelkamp plant for processing rice straw in 2017, another customer has now placed a similar project in the Siempelkamp test center.
Wemhöner press line in Turkey
For the second time Wemhöner Surface Technologies has been confirmed as one of 460 companies from Germany as a “world market leader” in the segment of machinery and plant engineering. Wemhöner specializes in short-cycle press lines for melamine direct lamination and 3D Variopress lines. The search for German world market leaders is carried out via an index developed by the University of St. Gallen in cooperation with the Academy of German World Market Leaders. The index checks and evaluates companies and follows an objective and transparent selection process. Managed today by third-generation family member Heiner Wemhöner, Wemhöner short-cycle presses for direct melamine lamination have been a permanent fixture for over 40 years and Wemhöner is a world market leader in this area. Wemhöner also developed the Variopress, of which more than 900 of these production lines laminate three-dimensional components with thermoplastic foils, veneers and other deformable materials. This results in furniture fronts with highgloss surfaces, deeply structured designs and radiused fronts. Wemhöner 3D Varipress systems stand for an innovative understanding of finishing in the third dimension. Wemhöner is also active in industrial digital printing including its MasterLine digital printing systems. Wemhöner Surface Technologies was founded in 1925. Today more than 330 employees develop and produce the entire product portfolio at the parent plant in Herford. In 2005, the subsidiary Wemhöner (Changzhou) Machinery Manufacturing Co. Ltd. was founded in China, followed by the opening of a production facility in Changzhou in 2007. Just three years later, capacity at the plant was doubled and expansion continues today. 170 employees mainly produce Wemhöner membrane presses and short-cycle presses principally for the Asian market. In addition to the production site in China, the company has agencies in more than 30 countries.
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GRECON The GreCon FORMATOR constantly regulates the material distribution of the mat. The FORMATOR reduces material fluctuations to a minimum by using automatic control process within a production order and also within the individual board. This GreCon UPU 6000 full width scan control process is based on the detection of material fluctuations in the mat forming line. This measuring data is automatically fed to the upstream mat-forming tool, the segmented scalper, via a corresponding control circuit. The segmented scalper regulates the material distribution immediately by the specific activation of rollers that eliminate local fluctuations by lifting and lowering. This control process implements a specified target profile of the mass per unit area across the width of the mat. ● The new GreCon UPU 6000 provides a quality control system that prevents delamination rejects, instead of simply detecting problems after they occur. Manufacturers can now monitor lamination quality and detect problems in the production line, as they happen. The UPU 6000 provides immediate feedback data to detection trends in delamination, blisters or blows caused by inconsistent gluing or press problems. Operators have commented, “In day to day use, this equipment alerts us to press, material or other problems. It warns us at the first occurrence, which saves approximately 15 to 20 minutes of bad production.” In panel board production the system is installed after the press for immediate control of both gluing and pressing. ● GreCon FIBERVIEW is an optical inline measuring system that assesses the fiber quality. This system can control the adjustment of the refiner discs automatically. Numerous studies have confirmed a correlation between refiner setting and fiber quality. It is possible to use fiber quality data to develop a refiner adjustment control. The FIBERVIEW transfers the current actual values for the number of shives to the controller via the OPC interface. The respective controller adjusts the distance of the grinding discs so that the current number of shives always remains within the defined tolerance range.
RAUTE Automating panel repair is an obvious solution, but most attempts fail at overcoming challenges in defect detection and complexities of the flaws and blemishes that affect panel quality inherent in how specific trees grow. With limited raw resources, finding and assessing common defects like knot holes, splits, light and dark colored knots, cracks, and roughness accurately is crucial to repairing panels. Imperfections located near edges or combination areas that blend two or more defects are difficult to identify as well as repair. Accurately detecting the depth of defects can be tricky, and some automation attempts compensate by overfilling repairs, which is costly, wastes resources, and takes longer to cure and finish.
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Raute’s Smart Panel Repair Line advances panel resurfacing with Mecano’s color and 3D analyzer technology, relying on multiple variations of high-resolution images to precisely detect every type of imperfection. 3D and layered images accurately determine depth and categorize multiple imperfections, including micro defects and fine cracks that are difficult to see by the naked eye but affect overall grade value instantly. After visual defect detection, analyzers manage Raute panel repair wood species and defect type to accurately determine if a repair is required for panel integrity. Cartesian robots, renowned for their precision and dependability, accurately apply the correct amount of material, eliminating overfill and reducing costly resource use. Raute’s Smart Panel Repair Line can detect, resurface, and grade panels fast, up to 30 meters per minute. That’s an average of about 1 panel every 6 seconds. Raute’s Smart Panel Repair Line significantly increases capacity and improves on every aspect of panel resurfacing to produce better quality panels. Less raw material. Less human resources. Less time. And all with less cost. The bottom line? Your significantly improved bottom line.
USNR USNR systems prioritize quality control throughout the entire veneer production process from peel quality to how it is clipped and sorted for drying, resulting in the highest quality veneer. BlockLogix scans each block to determine the best position for the lathe in the peeling process. Veneer then travels downstream to the Ventek-brand NV4g and GEM systems where it is scanned for defects, grade and moisture. Proper USNR dry veneer grading clip decisions are made and defects removed. Next, the Veneer Analysis System (VAS) measures veneer thickness and sheet clip width, grading and sorting it based on moisture, before it’s stacked and sent to the dryer. Veneer drying is controlled by Sequoia Sentry, a dryer management control system. It is the most technically advanced system for detecting moisture in dry veneer and controlling dryer speeds, with reported improved efficiency in the range of 20%. It incorporates both the veneer temperature and veneer thickness into the moisture level calculation, making it the most accurate moisture and dryer control system. Sequoia Sentry takes the guesswork out of moisture level setPanelWorld • SEPTEMBER 2019 • 43
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tings and reduces the cyclic periods of over- or under-dried veneer. This level of temperature monitoring and dryer speed control is shown to produce the highest quality veneer while maintaining visual grade. After the veneer is dried, Sequoia Sentry runs additional quality control checks before the veneer is routed to the GSs2000, the most accurate dry veneer grading system. The system handles a wide range of variables without a decrease in performance. The GSc2000 can achieve 95% on-grade performance at production speeds over 500 FPM.
WESTMILL Westmill’s patented WestVac Dryer Emission Control & Seal System combined with our innovative 2PEx Dryer Humidity Control & Exhaust Management System form the most highly effective dryer exhaust and emission control system. Westmill’s new 2PEx dryer exhaust extraction system is unlike any other dryer exhaust management system. The 2PEx system provides unparalleled control of the humidity ratio along the entire dryer’s length which results in the best veneer quality. Quite simply: by providing separate extraction points at both the green end and the dry end of the dryer, we can control the humidity migration to either or both ends of the dryer vs. venting the entire dryer’s exhaust from the green end single point exhaust, and starving the dry end for moisture. By
pulling the high humidity from the green end down to the dry end, the 2PEx creates a higher average humidity ratio within the entire dryer. This increases the “flash-point” re- Westmill illustration of 2-PEX system ducing fires, allows higher temperature drying, increases production all while increasing veneer quality. The WestVac Dryer Emission Control & Seal System seals the dryer’s end walls to keep the fresh air out while maintaining the optimum humidity level inside the dryer. All of this is accomplished via the system’s Re-Intro-Duct which draws any escaped heat-energy, VOCs and humid dryer gases back into the drying chamber by way of low-pressure vacuum created by the main circulation fans. The amount of vacuum in the system is adjustable and can be automatically or manually operated. Westmill’s humidity control system benefits include: —Increased dryer production —Greatly improved veneer quality —Reduced energy consumption —Reduced risk of fires
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CANADA PROPOSES FORMALDEHYDE EMISSIONS FROM COMPOSITE WOOD PRODUCTS REGULATIONS n late June the Canadian government published its proposed Formaldehyde Emissions from Composite Wood Products Regulations for public comment. The stated objectives of the regulations are (1) to reduce potential health risks by putting limits on allowable formaldehyde emissions from composite wood products and (2) to align with similar requirements in the United States in order to create a level playing field for Canadian, American and international businesses. While the scope of regulated product types and emission limits are identical to U.S. EPA TSCA Title VI regulation, the two regulations have a number of differing requirements. What follows are excerpts from the Canadian government’s Regulatory Impact Analysis Statement (this statement is not part of the regulations document).
I
ISSUES Composite wood products are a significant source of formaldehyde in indoor environments. Formaldehyde in indoor air can cause irritation of the eyes, nose and throat and can worsen asthma symptoms, especially in children. At higher levels, such as those that have been measured in some workplace environments, formaldehyde has been associated with cancer of the nasal passageways. At present, there are no Government of Canada regulations that set out
limits for the amount of formaldehyde that can be used in composite wood products imported, sold or offered for sale in Canada, or on the level of formaldehyde emissions that these products can give off. Although voluntary industry standards do exist, testing indicates that some products currently imported and sold in Canada give off formaldehyde emissions that exceed the standard and could pose a risk to human health. In order to help reduce health risks to Canadians, the Government of Canada is proposing the Formaldehyde Emissions from Composite Wood Products Regulations. These regulations would be enacted under the authority of the Canadian Environmental Protection Act, 1999 (CEPA). These regulations would place limits on the allowable formaldehyde emissions from composite wood products imported into, sold or offered for sale in Canada. The proposed regulations would align Canadian formaldehyde emissions requirements for composite wood products with similar requirements in the United States. This alignment will help ensure a level playing field between Canadian and American businesses, and reduce unnecessary industry burden and economic costs associated with meeting the health objectives of the regulations.
BACKGROUND Formaldehyde is a colorless gas that has a wide variety of uses and sources. It can be dissolved in liquids and used as a preservative, and it is also often used as a component of glues or bonding agents. Formaldehyde gas has a sharp odor that is easily detectable at high levels. Formaldehyde can be created by both natural and anthropogenic (human activity) sources. Normal biological processes in humans and many other animals generate small amounts of formaldehyde, and low levels of formaldehyde are present in the natural environment. Higher levels of formaldehyde can occur indoors as a result of human activity. Some of the most significant formaldehyde sources include emissions from composite wood products and emissions generated by combustion, particularly cigarette smoking, use of fireplaces, and cooking fuels. Other sources of formaldehyde in homes include paints and varnishes, glues, floor finishes, and certain types of paper and cardboard. The health effects of exposure to formaldehyde have been well studied. While very low levels of formaldehyde do not pose a health concern, elevated levels of formaldehyde exposure are known to cause a number of human health concerns. Short-term exposure to high levels of formaldehyde can cause acute health problems, including irritation of the eyes, nose and throat, and may worsen asthma symptoms, particularly in children. Long-term exposure to lower levels of formaldehyde may also result in chronic problems, including respiratory symptoms and allergic sensitivity in children. At particularly high exposure levels, well above the levels where irritation and inflammation begin to be noticeable, formaldehyde exposure may lead to cancer of the nasal pas-
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sageways. Formaldehyde has been classified as a Group 1 carcinogen (i.e. considered carcinogenic to humans) by the International Agency for Research on Cancer (IARC). It is also listed as a toxic substance under Schedule 1 of the Canadian Environmental Protection Act, 1999. Formaldehyde has been extensively used in the manufacturing of composite wood products. Composite wood products are products that are made out of multiple smaller pieces of wood glued together. The most well-known examples are plywood and particleboard, but other composite wood products exist, such as medium density fiberboard and laminated wood products. Formaldehyde is often used as one of the chemicals in the glues that hold these composite wood products together. Over time, products that have been manufactured with formaldehyde-based glues and resins can give off formaldehyde emissions. These emissions are highest when the products are newly manufactured, and generally decline over time. Composite wood products have many uses in Canadian homes, including use in furniture (especially the use of particleboard in inexpensive bookshelves and similar items), flooring, and wall paneling and trim. Off-gassing of formaldehyde from these products can be one of the main contributors to elevated formaldehyde levels and exposure in Canadian homes. Today, formaldehyde use in the manufacturing of composite wood products is less common in Canada than it used to be, and when it is used, the quantities of formaldehyde are typically much lower than in historical uses. However, formaldehyde use in composite wood products is still common in some international jurisdictions. Imported composite wood products can have formaldehyde content and formaldehyde emission levels considerably higher than is typical of Canadian-made products. Statistics on total imports of formaldehyde-containing composite wood products are not available, but Canada does import significant volumes of products that may contain formaldehyde. In 2017, Canada imported $3.5 billion worth of manufactured wood products, including $1.5 billion worth of veneer, plywood and engineered wood products. Imports of veneer, plywood and engineered wood products have been steadily increasing since 2013, when they were only worth $1.1 billion. In 2017, Canada also imported $280 million worth of wood kitchen cabinets and countertops, $300 million worth of wooden office furniture, and $1 billion worth of “other” wooden household furniture. In almost all cases, imports come primarily from the United States and China. Imports from the United States are slightly higher for unfinished products and those that need to be installed. Chinese imports are slightly higher for finished wood products. The United States and China combined account for 60% to 80% of Canadian imports across most product categories that include composite wood products. Both the United States and China have maintained a fairly consistent market share of Canadian imports since 2010.
For context, while Canada imported $3.5 billion worth of manufactured wood products, domestic manufacturers produced $17.4 billion worth of manufactured wood products for export, and generated $11.2 billion in value added for the Canadian economy. So while Canada does import significant volumes of manufactured wood products, including composite wood products, the domestic manufacturing industry is significantly larger than the import sector. It is unknown what the formaldehyde content or emission rates are for imported composite wood products. The State of California has had a formaldehyde emission standard for composite wood products for some time and the U.S. Environmental Protection Agency (EPA) recently enacted a similar rule. It is expected that most U.S. imports would meet the California or EPA standard. Imports from China and other overseas countries are expected to have higher formaldehyde emission levels than U.S. imports; however, comprehensive testing of imports has not been completed. Some limited testing by the National Research Council of Canada has been done and showed that at least some imported products currently produce formaldehyde emissions above the California standard.
REGULATIONS The Government of Canada has introduced and modified a number of regulations over the years to help reduce formaldehyde exposure. Fuel combustion is a common source of formaldehyde and several recent fuel-related regulations have addressed formaldehyde emissions, including the following: ● Off-Road Compression-Ignition Engine Emission Regulations ● Off-Road Small Spark-Ignition Engine Emission Regulations In addition, the importation, advertisement, or sale of urea formaldehyde-based thermal insulation (ureaformaldehyde foam insulation or UFFI) has been prohibited in Canada since 1980. The prohibition was originally set out in Part I of Schedule I to the Hazardous Products Act to address formaldehyde-related hazards to human
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health posed by UFFI. In 2011, with the coming into force of the new Canada Consumer Product Safety Act (CCPSA), the prohibition was transferred to Schedule II of the CCPSA. Under the CCPSA, the prohibition applies to the manufacture, import, advertisement, or sale of consumer products that are urea formaldehyde-based thermal insulation, foamed in place, used to insulate buildings. Health Canada’s Residential Indoor Air Quality Guideline for formaldehyde provides recommended health-based maximum exposure limits for formaldehyde in Canadian homes. The short-term and long-term limits are as follows: ● Short-term exposure: 123 µg/m³ (100 parts per billion [ppb]) based on irritation of the eyes, nose or throat ● Long-term exposure: 50 µg/m³ (or 40 ppb) based on hospitalization for asthma in children Testing carried out in Canadian homes between 2007 and 2015 suggested that approximately 8% of Canadian homes had average formaldehyde levels above the recommended long-term exposure limit. These exposure limits are also considered to be protective against adverse health effects in all individuals, including children with asthma. At present, there are no Government of Canada regulations that set out limits for the amount of formaldehyde released from composite wood products that can be used in Canadian homes.
VOLUNTARY STANDARD In 2016, the Canadian Standards Association (CSA), working with industry and the Government of Canada, developed a voluntary standard for formaldehyde emissions from composite wood products. This standard is effectively the same as the one used in California. Products that are in compliance with the voluntary standard can be labeled as complying with the CSA standard. Most Canadian manufacturers have indicated that their products already comply with this voluntary standard. However, since the standard is voluntary, it is unknown whether all Canadian manufacturers currently meet the standard. Although comprehensive testing has not been carried out since the implementation of the standard, some limited testing by the National Research Council of Canada has been done and showed that at least some imported products currently produce formaldehyde
emissions above the CSA standard. In the United States, the California Air Resources Board (CARB) evaluated formaldehyde exposure and found that one of the major sources of exposure is from inhalation of formaldehyde emitted from composite wood products containing ureaformaldehyde resins. The CARB developed an airborne toxic control measure to limit formaldehyde emissions from composite wood products sold in the state. That measure has been in place since 2009. In 2010, the United States Congress tasked the EPA with developing national regulations to manage formaldehyde emissions. The Toxic Substances Control Act (TSCA) Title VI rule, entitled Formaldehyde Emission Standards for Composite Wood Products, was published in July 2016, finalized in December 2016, and republished with amendments in October 2018. This rule requires composite wood products sold in or imported into the United States to comply with emission standards based on the CARB standards and also expanded the CARB requirements for a number of other categories of composite wood products. The EPA rule also includes requirements pertaining to testing, labeling, tracking, record keeping, certification and stockpiling. The rule came into force on June 1, 2018, for most composite wood products and will come into force in March 2024 for laminated products. In the European Union (EU), mandatory testing and labeling of formaldehyde off-gassing from wood products exists or has been proposed in certain jurisdictions, including Germany, France and Denmark. Formaldehyde is currently being evaluated by France and the Netherlands under the Community Rolling Action Plan, based on concerns relating to human health. Under the EU’s chemical management regime “REACH,” registrants had until October 2017 to submit information regarding emission rates over time of formaldehyde into indoor air from major sources found in the indoor environment. Various other countries have also developed, proposed or implemented limits on formaldehyde emissions from wood products, including Mexico, Japan, Australia and New Zealand.
IMPACTS OF EPA RULE New national mandatory limits on emissions of formaldehyde from composite wood products in the United States could pose problems in Canada, both for human health and for Canadian businesses. If international companies that manufacture high-emitting formaldehyde composite wood products are no longer able to sell their products in the United States, there is a risk that they may try to dump those products on the Canadian market. It is unknown how significant this risk may be. But if Canada has less stringent regulations than the United States, there is a nontrivial risk that Canada could start to see significantly more imports of composite wood products that have high formaldehyde content. This would further increase the risk to the health of Canadians. On the manufacturing side, failure to align regulations with the United States could put Canadian manufacturers at a disadvantage. Most Canadian manufacturers of composite wood
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products sell their products in both Canada and the United States. If they face significantly different regulatory requirements in Canada and the United States, then they would be faced with three options: sell to only one market, which would result in a loss of sales; manufacture two separate product lines, one for each market, which would be inefficient; or manufacture a single product line that complies with both regulatory regimes, which would be costly and place them at a disadvantage relative to Canadian imports manufactured to a less stringent standard.
OBJECTIVES The primary objective of the proposed Canadian Regulations is to reduce potential risks to the health of Canadians from exposure to formaldehyde by putting in place limits on allowable formaldehyde emissions from composite wood products. The secondary objective of the proposed regulations is to align Canadian requirements for composite wood products with similar requirements in the United States, in order to help create a level playing field among Canadian, American and international businesses and reduce unnecessary costs to business associated with compliance with multiple regulatory requirements. In order to reduce compliance costs for Canadian companies, and to facilitate regulatory alignment and create a level playing field with the United States, the proposed regulations have been very closely aligned with the U.S. regulations. Emission limits under the proposed regulations are the same
as those in the U.S. regulations. There are some differences between the Canadian Regulations and the U.S. rule with respect to labeling, record keeping, and administrative requirements. For instance, the U.S. rule allows for compliance to be verified and reported on by third-party certifiers, whereas the Canadian Regulations require manufacturers to report directly to the Government. In addition, Canadian labels must be in both official languages, English and French, while the U.S. labels have no such requirement. These administrative differences have been included, and in some cases were required, to address unique Canadian circumstances and the Canadian legal and legislative framework. The administrative differences between the Canadian Regulations and the U.S. rule have been minimized where possible, and the few differences that exist are not expected to limit the ability of manufacturers to comply with the technical requirements of either regulatory tool. The proposed regulations would apply to the import, sale and offer for sale of composite wood products in Canada. With a few exceptions, the regulations would apply to composite wood products for indoor use in Canada. The proposed regulations would establish the following maximum emission levels for formaldehyde emissions from composite wood products: ● 0.05 parts per million (ppm) for hardwood plywood ● 0.09 ppm for particleboard ● 0.11 ppm for medium density fiberboard ● 0.13 ppm for thin medium density fiberboard ● 0.05 ppm for laminated products Composite wood products that emit formaldehyde gas above these levels could not be sold in, offered for sale in, or
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imported into Canada under the proposed regulations unless they are exempted from the regulations. Products such as pallets and packaging materials that are not intended to be kept in people’s homes, certain types of structural wood products, wood used in vessels and vehicles (other than mobile homes, motor homes, and recreational trailers), and a variety of highly specialized wood products would be exempted from the proposed regulations. A full list of the exemptions is included in the regulations. Non-exempt composite wood products that are to be sold in Canada must be tested to ensure they meet the regulatory emission limits, and labeled as meeting the requirements before they may be sold in, offered for sale in or imported into Canada. Product testing must be carried out on a routine basis, which is dependent upon the amount of manufacturing and product type, to ensure consistent emission levels (quality control). In
addition, product testing must be conducted on a quarterly basis by an accredited laboratory to demonstrate consistency between the routine quality control test results and the emission test results generated by an accredited laboratory. The specific requirements for accreditation are set out in the proposed regulations. In certain cases, testing may be required less frequently, such as for manufacturers that are using no-added formaldehyde or ultra low-emitting formaldehyde resins. The specific testing requirements and testing frequency vary depending on the type and volume of products being tested. The testing requirements under the proposed regulations would be essentially the same as the testing requirements under the U.S. rule. All products that are required to be compliant with the proposed regulations must be labeled prior to being sold or offered for sale in Canada. In some cases, if products are sold or offered for sale bundled together, then it may not be necessary
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to label each individual item. Labels must be bilingual (English and French) and meet the other label requirements provided in the proposed regulations. Some minor differences exist between the U.S. labeling requirements and those under the proposed regulations, including, but not limited to, the bilingual requirement. Certain products may qualify for alternative labeling if they meet additional standards. Products that are made without the use of formaldehyde can be labeled as “no-added formaldehyde” products. Some other products may qualify to be labeled as “ultra low-emitting formaldehyde” products. In both cases, there are alternative testing requirements that must be met in order to qualify for the alternative label. Those requirements are outlined in the proposed regulations. Manufacturers of panels and laminated products are required to keep records of product-testing results, records of production levels, the name of the individual, company or facility responsible for testing, customer information, shipping information, and various other records as specified in the regulations. Manufacturers must provide an annual report to the Minister of the Environment containing most of this same information. Importers, manufacturers of composite wood products, and retailers are required to document where their composite wood products came from and that their supplier verifies that the products are compliant with the regulations. They must also verify that the products they buy and sell are labeled with the appropriate formaldehyde emission labels. All records must be maintained for a period of at least five years, and must be made available to the Minister of the Environment, or to purchasers, upon request. These regulations would come into force six months after publication of the final regulations in the Canada Gazette, Part II. Most products imported, sold or offered for sale in Canada would need to comply with the applicable standards and regulatory requirements once the regulations come into force, six months after publication. However, some laminated products would be exempted from the emission requirement until five years after the regulations come into force. Additionally, products that were already manufactured or imported into Canada
prior to the regulations coming into force would be exempted from the emission requirements and could still be sold provided that they are sold within three years from when the regulations come into force.
COST SUMMARY The cost of the proposed regulations is expected to be low, meeting the threshold for “low impact” regulations with total costs estimated to be below $10 million in present value terms over a 10-year period. The total costs of the proposed regulations are estimated to be $8.9 million over the 10-year total analytical period of 2020 to 2029. Out of 580 Canadian production firms directly impacted by the proposed regulations, it is expected that most Canadian manufacturers already meet the voluntary CSA standard, and are therefore already compliant with the proposed regulations, so the incremental compliance costs to them would be negligible. For those Canadian manufacturers who do not currently meet the voluntary CSA standard but sell products in the United States, it is expected that, in light of the new EPA standard, the majority of these companies will be upgrading their processes in order to continue selling in the United States. If they do upgrade in order to sell their products in the United States, then their products would also comply with the Canadian proposed regulations. The incremental additional cost to these companies of complying with the regulations would therefore also be negligible. By aligning emission limits and requirements as much as possible with those of the United States, the costs to Canadian companies would be greatly reduced, and the level playing field for Canadian, American and international companies would provide economic benefits for Canadian companies. The incorporation by reference of well-established technical standards developed by expert domestic and international agencies would allow for consistent understanding and application of the regulations. When better or more efficient testing methods become available, or when testing accreditation requirements change, the standards can be reviewed and updated PW by the agencies.
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PROJECTS THREE TIMES IS A CHARM
First board at Novopan in Quito, Ecuador
First board at Wanhua Ecoboard in Tongling, Anhui, China
The production of the first board is a milestone for all partners involved in any new wood-based panel plant.
Within just four days in mid-June, three new Dieffenbacher lines produced first boards, giving plant operators and Dieffenbacher plenty of reasons to celebrate. The Chinese Wanhua Group and its subsidiary, Wanhua Ecoboard, were doubly pleased. On June 10, the first board rolled off the production line at their Jingzhou site in Hubei Province, while just three days later board production began in Tongling, Anhui. Wanhua produces particleboard made from rice straw on both lines. Wanhua has relied on Dieffenbacher expertise in alternative raw materials since 2015. The plants, which began operations in June, were orders number four and five between the two companies. Three more lines, which will produce particleboard and also MDF and fine surface OSB from straw content, are planned. The commissioning of the two Wanhua plants marked the debut of the Dieffenbacher CPS+ continuous
press in China. Another first board celebration took place on June 12 near Quito, Ecuador. Here, a new Dieffenbacher particleboard plant started production for Novopan del Ecuador. Dieffenbacher has a long-standing partnership with Novopan. Dieffenbacher began servicing Novopan’s first Quito plant in 2008, when Metso sold its wood-based panel business to Dieffenbacher.
BOISE UPGRADES FLORIEN LATHE Boise Cascade at Florien, La. is continuing its improvement path for its #1 lathe with new lathe carriage and roller bar assemblies from USNR. This follows closely on the heels of a new core drive ordered earlier in 2019. The new carriage is manufactured from cast steel and includes a direct drive roller bar with precision roll assembly and pressure bar heads, cast steel knife
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bar with knife bar heads, and hydraulic knife clamps. The roller bar is supplied with servo vertical bar height adjustment. The roller bar applies torque to the block surface, reducing spinouts and plug-ups by allowing a free pass-through of slivers. The precision fluted roll provides improved recovery and production, particularly from low quality blocks.
LOGSTACKERS HEAD TO CANADA
New generation 60 ton Logstacker
PROJECTS
adding a number of new improvements coveted by operators and maintenance staff alike, such as: —Seriously fast hoist speeds —Lighted ground level service bay for easy routine maintenance —Lighted stairways for safe and easy access on and off the machine —Newly designed cooling package with easy maintenance access —More spacious and comfortable cab with improved visibility —Longer component service life and maintenance intervals The four-wheel drive Wagner L4120 maintains traction in the toughest conditions while the two-wheel drive L120 is perfect for improved yards, and boasts even better fuel efficiency and a tighter turning radius. Whether you’re handling cut-to-length or treelength logs, Wagner Logstackers can handle it all quickly, efficiently and for the lowest total cost. Wagner Logstackers are designed and built in Sherwood, Ore.
Allied Systems Co., parent company for Wagner Logstackers, is excited about its recent shipments of two new 60 ton operating capacity Wagner Logstackers into Canada. Wagner has long been known for its durable single pass Logstacker, and the new generation models build on that legacy by
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HEXION COMES BACK FAST
Hexion Inc. reports it has successfully completed its balance sheet de-leveraging and emerged from Chapter 11. As a result of this process, Hexion states it has reduced its debt by more than $2 billion, received an infusion of $300 million in equity capital through a rights offering, and raised approximately $2 billion in exit financing. With a strengthened capital structure and substantial free cash flow after debt service, Hexion says it is now positioned to make substantial reinvestments into its businesses to fuel strategic growth and drive value for its stakeholders. Throughout the bankruptcy court-supervised process, Hexion’s global operations continued uninterrupted. The deleveraging plan has provided for payment in full to the company’s trade creditors. “We are moving forward with significantly less debt and greater financial flexibility, which enhances our competi-
tive position and ability to create longterm value for our stakeholders,” says Craig Rogerson, president and CEO. “As an appropriately capitalized market leader with substantial free cash flow generation capabilities and a lower interest burden, we will continue to enhance our value-creating platform by accelerating new product development. Our growth strategy will be driven by investments in innovative products using our research and development capabilities and strategic partnerships, capitalizing on our global manufacturing footprint and commitment to sustainability. Going forward, we are wellpositioned to take advantage of our operational momentum.” Rogerson adds that Hexion’s expedited emergence is a testament to the hard work and dedication of its associates, and the continued support of its customers and suppliers around the world. Hexion reports it is the global leader in Forest Products and Epoxy, Phenolic and Coatings resins, maintaining #1 or
#2 market positions representing approximately 80% of sales. Through its continued investments in R&D, between 2014 and 2018 Hexion has derived approximately 20% of its total revenues from new products. Hexion continues to further align its product portfolio with leading sustainability practices. The company’s forest product resins allow natural, renewable resources to be used in building products instead of energy intensive steel and concrete, and the use of wood in building construction allows for the long-term sequestration of carbon.
MCCLURE JOINS ALTEC AT DEMCO ALTEC named Allan McClure as General Manager of its manufacturing facility in Diboll, Texas (Demco Manufacturing, Inc). Well known in the industry, McClure brings 43 years of experience in the veneer and plywood industry in plant operations, machinery
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LINES manufacturing and technical field service, particularly on the green end. Starting from the ground up McClure spent 12 years on green ends in the mills, followed by 12 years at Calvert Engineering, managing the lathe service teams working on a variety of rotary veneer lathes. For the last 20 years McClure was half of the Feltham-McClure Company, specialists in rotary veneer lathes and all things mechanical around the green end. This included service, installation supervision and troubleshooting. ALTEC also named Randy Watts as a Field Service Technician based out of the manufacturing facility in Diboll. Watts has 27 years of experience on veneer green ends in operations and maintenance. During those years Watts has predominantly worked on and specialized in everything around the lathe deck, rotary veneer lathes and all things mechanical around the green end. This includes service, installation supervision and troubleshooting.
Watts’ addition to the team increases Altec’s breadth of expertise and field service capability.
FROM DIEFFENBACHER TO DIEFFENBACHER With Christian Dieffenbacher joining the Management Board of the familyrun machine and plant manufacturer at the beginning of 2016, Dieffenbacher set a course for transferring management responsibility from the fourth to the fifth
Christian and Wolf-Gerd Dieffenbacher
generation. As a result, effective July 1, Wolf-Gerd Dieffenbacher has resigned from the Management Board. Wolf-Gerd Dieffenbacher was actively involved in the company for more than 40 years and served as a member of the Management Board since 1985. In times of tremendous change, he helped to develop the pure press manufacturer into an internationally leading supplier of complete plants for the wood-based panels, composites and recycling industries. During this period, the company’s turnover increased from 36 million euros to more than 400 million euros. Wolf-Gerd Dieffenbacher now becomes part of the Board of Advisors and will remain associated with the company in various other capacities. The Dieffenbacher Management Board now consists of the three remaining members: Christian Dieffenbacher,
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LINES Volker Kitzelmann and Lothar Fischer. In addition to his other responsibilities, Christian Dieffenbacher becomes CEO and spokesman for the Management Board. The roles of CFO Volker Kitzelmann and CTO Lothar Fischer remain unchanged. Jakob Dieffenbacher founded the company in 1873 in Eppingen, Germany as a manufacturer of fruit, wine and oil presses. It was the third generation family members who began building presses for particleboard and veneer in 1954.
RAUTE OPENS SECOND RUSSIA SERVICE CENTER Raute Group’s new Service Center has been inaugurated in Kirov, Russia. Kirov Service Center, Raute’s second service center in Russia, was opened to ensure Raute’s capability to meet its customers’ needs better and serve the Kirov region plywood mills more effectively by offering shorter delivery times for spare part deliveries and local services. ➤ 60
IMAL-PAL GROUP AT LIGNA Imal-Pal Group and Panel Alliance showcased a wide range of equipment and solutions during Ligna in Hannover, Germany in late May. Visitors showed a keen interest in the “Show Room” where a range of equipment was on display, such as the new gauge MMW for on-line control of mat weight distribution, moisture content and thickness. Numerous solutions for online quality control and laboratory equipment were shown. The Dynasteam mat steam injection system, 108 systems of which have been sold worldwide, and the Hi-Jet high pressure resination system for MDF, PB and OSB, with more than 193 systems sold and installed., received considerable attention. Showcased for the first time was the ASR Automatic Sharpening Room, a fully automatic knife sharpening system for knife ring flakers equipped with a 6axis robot that is able to carry out all the sharpening operations within 60 minutes. Another innovation was the Stepper Screen, a new self-cleaning roller screen that can solve the problem of recycled wood containing fabric, ropes etc. thanks to its patented alternating movement. Meanwhile Panel Alliance completed another successful edition of the Ligna show. Panel Alliance was created by GLOBUS, PAL, TRASMEC and IMAL from Italy, RECALOR from Spain and VYNCKE from Belgium and is a group of independent companies where each company is an expert in its own core business.
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58 ➤ Kirov Service Center provides maintenance and spare parts warehouse services to Raute’s customers. Within a radius of 400 kilometers, there are more than 10 plywood mills. Technology services are offered in Russia also by Raute Service LLC, which is a Raute Group company in St. Petersburg, established in 2005. The city of Kirov is located 1,500 km east of St. Petersburg. “The opening of the new Kirov Service Center marks an important milestone for Raute Service LLC in terms of providing local services to a growing veneer, plywood and LVL industry in the local market,” says Jouni Putkonen, vice president, Market Area Russia (CIS). Raute’s strategy is to establish local service points close to its customers in order to be able to offer fast service utilizing global knowhow. Raute’s Finnish units include the head office and main production unit in Nastola, Lahti and a production and development unit specializing in machine vision and moisture analyzing technolo-
gy in Kajaani. The Group also includes eight subsidiaries. The Group’s other production units are located in the Vancouver area of Canada, the Shanghai area of China and in Pullman, Wash., USA. Additionally, customer and maintenance services are offered by the subsidiaries in St. Petersburg, Russia, Santiago, Chile and Singapore. In addition to the new service center in Kirov, Russia, Raute has local service points in Estonia, Latvia, Poland and Australia.
ARCLIN BUYS PAPER TREATING FACILITY Arclin, a chemistry-based manufacturer of engineered products for the building, design, transportation and other industries, completed the acquisition of SURTECO’s North America decorative paper treating facility in East Longmeadow, Mass. Acquisition of the facility expands Arclin’s footprint in North America,
complementing the company’s existing treating operations in Tacoma, Wash. and Cobourg, Ontario. Arclin provides treating for its own portfolio of designs for TFL and has significant custom-treat capacity for TFL customers. Combined with the company’s industrial surface treating assets, the company will now operate five treating facilities across North America in addition to six chemical facilities.
SAW TOOLS FIRMS CONTINUE RELATIONS Grasche USA and Ceratizit Group of Luxembourg have signed a 10-year extension to their dealer agreement regarding the distribution of knives and profile blanks in North America. The working partnership agreement was formalized at the recent Ligna Fair in Hanover, Germany. Since the launch of their collaboration in 2014, sales for both companies have grown steadily. The close working
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S U P P LY
LINES relationship to promote the “Go Chrome” carbide grade program has been very successful, and it has now been further expanded with the addition of the new KCR18+ grade, providing a comprehensive offering suitable for all wood-processing applications. “Grasche USA carries an extensive local inventory of knives and profile
blanks that allow their customers fast delivery times and local support,” says President and owner Richard Comer. Andreas Olthoff, managing director of Ceratizit, thanked Grasche for five years of service and wished them all success for future sales growth in North America. Grasche is a U.S. manufacturer of custom saw bodies ready for tipping.
The saw bodies are laser-cut, heat-treated, reamed, surface-ground, and hammered. Each saw is built in the U.S. with German cold-rolled saw steel using European machine and manufacturing processes to ensure the tightest tolerances possible.
DEERE COMPLETES TRAINING FACILITY
John Deere’s new forestry training facililty
John Deere recently completed the construction of a 7,500 square foot facility in Coal Valley, Ill. to better meet internal training demands, along with supporting customer visits and events. The building is part of the Construction & Forestry Training Campus and includes three classrooms that can be used separately for training purposes, or combined to hold more than 250 people for larger events. In addition, there is nearly 4,000 square feet of covered canopy space for outdoor training and equipment walkarounds. “The primary function of this new facility is to provide much-needed additional classroom space for dealer sales staff and technician training,” says David Reilly, manager, worldwide training, John Deere Construction & Forestry. “Training is a core part of our program, but beyond that, the C&F Coal Valley Training Campus also hosts other important events throughout the year.” The facility will also include a John Deere simulator—further bridging the gap between the classroom and jobsite. Onsite events include customer-specific activities where they can demo equipment and interact with John Deere experts. “With this new facility customers and dealers can walk out of the classrooms and directly into the demonstration area,” adds Tim Hilton, manager, Demonstration Sites, John Deere Construction & Forestry. “We’re excited to share this new experience with dealers, technicians, customers and media.” 62 • SEPTEMBER 2019 • PanelWorld
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CLIPPINGS
RELIABILITY IS KEY FOR ROSEBURG
Roseburg announced that Chris Metcalf has joined the company as Director of Reliability. In this newly created role Metcalf will oversee the analysis of reliability and maintenance practices and needs across the company and implement solutions to create a high-performance manufacturing culture, Roseburg stated. “As Director of Reliability, Chris will build a small team of
company resources dedicated to helping our plants define and implement best practices for asset management and reliability,” Senior Vice President of Operations Jake Elston says. “Equally important, Chris will also work with our operational units to help determine what local resources are needed to drive improvement in our business.” For the past 15 years, Metcalf has led improvements in maintenance and reliability for several major manufacturing organizations, building and leveraging large-scale ERP CMMS/EAM and business intelligence systems. Metcalf holds a Bachelor of Science degree in Industrial Engineering from the University of Iowa.
BURFORD NAMED VP OF PLYWOOD Jeremy Burford has assumed the role of RoyOMartin’s Vice President of plywood. Hired in 2006, Burford joined the Chopin, La. plywood facility as dry-end manager and most recently served as plant manager. Burford’s career in wood products began upon completion of his Bachelor of Science in Mechanical Engineering from Louisiana Tech University and has included responsibilities in operations management, capital projects, and site improvement, all the while continuing his education through the Louisiana State University Executive Education Program.
EVERGREEN ADDS SEATTLE OFFICE Evergreen Engineering, Inc., is adding a location in the Seattle, Wash. area. “We wanted to better serve our major wood products and pulp & paper clients in Washington state,” comments Evergreen Business Development Director Aaron Edewards. “We also wanted to take advantage of the pool of local talent.” Kevin Tangen, formerly based at Evergreen’s Eugene, Ore. office, will lead the staff as Project and Office Manager. He will be joined by mechanical engineer Erik Lasher, also formerly of Eugene, and newly hired Senior Project Manager Jeffrey Tuma. A complement of locally hired designers and drafters will round out the team. Established in 1985, Evergreen Engineering, Inc., now has offices in Eugene, Seattle, and Atlanta, Ga.
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VENEER/PANEL SUPPLIERS
DIRECTORY ■ Taiwan
ASIA
EUROPE
GREAT GIANT INC.
■ India
■ Austria
VENEER AND VENEERED PRODUCTS 260 Dachang Road Niao Song District Kaohsiung, Taiwan 833 Tel: 886 7 3790270 Fax: 886 7 3790275 E Mail: jc.giant@msa.hinet.net
■ Vietnam NEXT CLOSING: September 24, 2019
AUSTRALIA/OCEANIA
■ Malaysia
Manufacturer In Malaysia CARB P2 / EPA Certified Fancy plywood/MDF/ Particle Board/ Blockboard Layon Veneer, Veneer Parquet, etc. Lot 488, Jalan Jati Kiri, Kg. Perepat 42200 Kapar, Selangor Darul Ehsan, Malaysia Tel: +603 3259 1988 • Fax: +603 3259 1886 E-mail: bungaraya@bungarayapanel.com Website: www.bungarayapanel.com
SPECIALISTS IN AUSTRALIAN & PACIFIC VENEERS FSC & PEFC ECO-CERT Veneers from around the world Over 150 species in stock Reconstituted veneer/spliced faces/rotary veneers Website: Email: Tel: Fax:
www.briggs.com.au admin@briggs.com.au +61 2 9732-7888 +61 2 9732-7800
www.fsc.org FSC™ C004099 The mark of responsible forestry
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VENEER/PANEL SUPPLIERS DIRECTORY
NORTH AMERICA
■ Poland
■ Idaho
■ Canada ■ British Columbia Knotty Idaho White Pine Western Red Cedar Red Alder Clear White Pine & Ponderosa Pine Clear Vertical Grain Douglas Fir, Hemlock, & Cedar
6670 - 144th Street, Surrey, BC V3W 5R5 Plant: (604) 572-8968 Fax: (604) 572-6608
Producers of high quality fine face veneers. Specializing in species indigenous to the West Coast. We manufacture Music grade solids and veneers. We also offer custom slicing, cut-to-size and log breakdown. Fir • Hemlock • Spruce • Pacific Maple (Figured and Plain) • Alder Western Red Cedar
■ Romania
■ Ontario
P.O. Box 339 Post Falls, Id. 83877 208-773-4511 FAX 208-773-1107 email: info@idahoveneer.com
NEXT CLOSING: September 24, 2019 ■ Indiana Amos-Hill Associates, Inc.
A FULL SERVICE PLYWOOD & VENEER COMPANY WE OFFER: Short turnaround time, In-house veneer mill—ROTARY, FLAT CUT, RIFT and QUARTERS, Custom pressing capabilities, Architectural specified plywood jobs, Huge veneer and core inventory, Over 100 natural species and engineer veneers in stock, All sizes and thicknesses–6'x4' to 5'x12', Internal logistics for fast on-time deliveries Contact us: Birchland Plywood-Veneer Ltd. TeL: 705-842-2430 • Fax: 705-842-2496 Visit www.birchlandplywood.com to view our “Live Log Program”
■ Spain
PRODUCERS OF SLICED AND ROTARY CUT VENEERS
SUPPLIERS OF FSC SPECIES • All figured species (Eucalyptus, Anegre, Sycamore...) • All pommeles and African species. • All burls (Ash, Elm, Olive, Walnut, Oak...) • Smoked and dyed veneers. Veneer layons.
We supply furniture, panel and architectural grades.
Quality Veneers Manufacturers of Decorative Hardwood Veneer Domestic and International Markets Species include: Walnut, White Oak, Red Oak, Hard Maple, Cherry and Birch “Quality is the Lifeblood of our Business” 112 Shelby Ave. ◆ P.O. Box 7 Edinburgh, IN 46124 Phone: 812-526-2671 ◆ Fax: 812-526-5865 E-mail: info@amoshill.com Website: www.amoshill.com The mark of responsible forestry FSC Supplier: SCS-COC-002445 * SCS-CW-002445
Reserve your space today. Call Melissa McKenzie 800-669-5613
VALENCIA – SPAIN Tel: +34-96126 5400 Fax: +34-96126 5144 timbercom@timbercom.com
www.timbercom.com
■ Switzerland
■ United States ■ Georgia
A new “Dimension” in Veneer & Plywood
Dimension Plywood Inc.
Custom Architectural Plywood & Doors 415 Industrial Blvd. • New Albany, IN 47150 Tel: 812-944-6491 • Fax: 812-944-7421
Dimension Hardwood Veneers, Inc.
Rotary & Sliced Veneers 509 Woodville Street • Edon, Ohio 43518 Main Office - Tel: 419-272-2245 • Fax: 419-272-2406 www.dimensionhardwoods.com FSC-C041275
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VENEER/PANEL SUPPLIERS DIRECTORY NORSTAM VENEERS, INC.
■ Michigan
Proud to announce we have the “Newest Veneer Mill in the World”
A new “Dimension” in Veneer & Plywood
Dimension Hardwood Veneers, Inc. Rotary & Sliced Veneers 509 Woodville Street • Edon, Ohio 43518 Main Office - Tel: 419-272-2245 • Fax: 419-272-2406
MANUFACTURER OF QUALITY HARDWOOD AND SOFTWOOD VENEERS
Green & Kiln Dried Hardwood Lumber
Dimension Plywood Inc.
P.O. BOX 32 HWY. 135 BUS: 812.732.4391 MAUCKPORT, IN 47142 FAX: 812.732.4803 EMAIL: info@norstam.com
RSVP is proud to offer a full line of imported and domestic veneer that includes burls, crotches and highly figured woods. If you would like more information pertaining to these products or others we offer please contact us directly or visit our website.
4920 N. Warren Dr. • Columbus, IN 47203 Ph: 812-375-1178 • Fax: 812-375-1179 www.RSVPveneer.com
■ Ohio
Custom Architectural Plywood & Doors 415 Industrial Blvd. • New Albany, IN 47150 Tel: 812-944-6491 • Fax: 812-944-7421 www.dimensionhardwoods.com FSC-C041275
■ Minnesota BUFFALO VENEER & PLYWOOD CO. Quality Plywood, Six decades strong! Stock Panels Counter Front Panels All Thicknesses and Cores NAF, FR and MR Availability Domestic and Imported Veneers CARB P2 Certified 501 6th Ave. NE - Buffalo, MN 55313 Tel: (763)682-1822 Fax: (763)682-9769 Email: sales@buffaloveneerandplywood.com Website: www.buffaloveneerandplywood.com
■ Mississippi
Reserve your space today. Call Melissa McKenzie 800-669-5613
Reserve your space today. Call Melissa McKenzie 800-669-5613 ■ Kentucky
MAGNOLIA FOREST PRODUCTS, INC.
Universal Veneer Mill Corp.
DISTRIBUTORS OF SYP Plywood & Lumber OSB Cut to size
Manufacturing and Sales Sliced Harwood Veneers Custom Cutting Available
1-800-366-6374
1776 Tamarack Road Newark, OH 43055 Ph: (740) 522-2000 Email:
www.magnoliaforest.com Terry, MS J.I.T. & P.I.T. Nationwide
info@universalveneer.com
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VENEER/PANEL SUPPLIERS DIRECTORY ■ Oregon
ESTABLISHED 1972
Architectural Paneling, Door Skins, Custom Cabinet Package and Furniture Plywood ● Panel sizes up to 5' x 12' ● 4', 5' and cross-grain sanding capability ● Veneer manufacturing to 14' lengths ® ● FSC Certified ● NAUF products available ●
2323 Cross Street ● Eugene, Oregon 97402 Sales: (541) 461-0767 ● Fax: (541) 461-0738 Email: sales@westernpanel.com web site: westernpanel.com
Proudly serving our clients in the hardwood plywood sheetstock, plywood component, solid wood component, face and core veneer markets for over 40 years. Looking forward to applying our worldwide knowledge and resources to help create the solution you need. inquiry@pittsburghforest.com Office: 724.969.5000 375 Valleybrook Rd, McMurray, PA 15367
Reserve your space today.
■ Vermont
■ Pennsylvania
LOCATE VENEER & PLYWOOD PRODUCTS AND SERVICES WORLDWIDE.
North America’s largest manufacturer of fancy face rotary veneer. Offering FSC certified veneer products in Red Oak, Hard Maple, Birch, Ash, Tulip Poplar, Basswood in Stock Panel & Cut-to-Size Lay-ons as well as unspliced veneer .4mm thru 1.5mm thickness
Plain sliced Alder and Aromatic Cedar faces and flitch stock are regularly available. Also offering domestically produced FSC Mixed Credit/CARB Phase II Compliant Aspen platforms - both long grain & cross grain dimensions in a variety of thicknesses.
Contact Sales at 802-334-3600 • Fax: 802-334-5149 www.cfpwood.com • 324 Bluff Rd. • Newport, VT 05855
NEXT CLOSING: SEPTEMBER 24
EMPLOYMENT OPPORTUNITIES
5394
PROFESSIONAL SERVICES DIRECTORY
Call Melissa McKenzie 800-669-5613
THE Forest Products Group
5515 S.E. Milwaukie Ave, Portland, Oregon 97202 503-230-9348 Fax: 503-233-2051 www.kh2aengineering.com Email: kh2a@kh2aengineering.com
Jon Olson
CONSULTANTS & ENGINEERS FOR THE FOREST PRODUCTS INDUSTRY Feasibility Studies, Cost Estimates, Complete Project Design, Structural, Civil, Mechanical and Electrical Design
Tel: (800) 985-5191
1009
SEARCH NORTH AMERICA, INC. IT'S YOUR MOVE...
FOREST PRODUCTS RECRUITING SINCE 1978
The Jobs You Want — The People You Need
1615
9237
Custom search & recruitment services for the complete range of composite panel and related careers in the U.S., Canada and Europe. www.olsonsearch.com
4231
jon@olsonsearch.com
WWW.SEARCHNA.COM
CONTACT CARL JANSEN AT 541-593-2777 OR Carlj@SearchNA.com
Top Wood Jobs Recruiting and Staffing George Meek geo@TopWoodJobs.com www.TopWoodJobs.com (360) 263-3371
3779
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EVENTS OCTOBER
FEBRUARY 2020
6-8 • Composite Panel Assn. Fall meeting, Grand Hyatt Regency, Denver, Colo. Call 703-724-1128; visit composite panel.org.
27-March 2 • IndiaWood 2020, Bangalore International Exhibition Centre, Bangalore, India. Call +91-80-4250 5000; visit indiawood.com.
12-16 • Intermob, Tüyap Fair Convention and Congress Center, Istanbul, Turkey. Call +90 212 867 11 00; visit intermobistanbul.com/en.
NOVEMBER 2-5 • APA-Engineered Wood Assn. annual meeting and Engineered Wood Technology Assn. Info Fair, JW Marriott Star Pass, Tucson, Ariz. Call 253-565-6600; visit apa wood.org.
DECEMBER 3-6 • Woodex, 16th International Exhibition of Equipment and Technologies for Woodworking and Furniture Production, Crocus Expo, Moscow, Russia. Visit woodexpo.ru/en-GB/.
Check us out online at
panelworldmag.com
Listings are submitted months in advance. Always verify dates and locations with contacts prior to making plans to attend.
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This issue of Panel World is brought to you in part by the following companies, which will gladly supply additional information about their products. ADVERTISER
Airstar Altec Integrated Solutions Argos Solutions Biele Automation Process Casey Industrial CMC-Texpan Coil Manufacturing Con-Vey Keystone Corvallis Tool Custom Engineering Dieffenbacher GmbH Doescher Microwave Systems GmbH Electronic Wood Systems Elliott Bay Industries Evergreen Engineering Fezer Forbo Siegling GmbH Grecon Grenzebach Maschinenbau GmbH Hashimoto Denki Hexion Imal S.R.L IMEAS S.P.A. INTEC Engineering GmbH IPCO Johnson & Pace Kelzenberg Lap GmbH Laser Applikationen Limab Meinan Machinery Works Metal Detectors Mid-South Engineering Nondestructive Inspection Service Pal S.R.L Panel Alliance Peninsular Cylinder Progressive Systems Raute Wood Roo Glue Samuel Packaging Systems Group Scheuch GmbH Sherdil Precision Siempelkamp Gmbh Signode Southern Environmental Stela Laxhuber GmbH Sweed Machinery Taihei Machinery Works U S Metal Works USNR Uzelac Industries Wemhoner Surface Technologies West Salem Machinery Westmill Industries Willamette Valley Woodex Moscow Woodtech Measurement Solutions
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