Millwide Insider #37

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Insider

THE MAGAZINE FROM USNR | ISSUE 37

CARRIER LUMBER INVESTS IN PLANER INFEED, IMPROVES ITS PROCESS

USNR’S NEW BOARD FEEDER THE LATEST TREND IN INSPIRED DESIGN

CAMBIO 800 DEBARKER MAKING BIG GAINS AT CARTER HOLT HARVEY


CONTENTS

Millwide Insider ISSUE 37

We’ve done it again USNR introduces more new products, designs and processes than any other manufacturer world wide. We make it a practice to leverage the exper tise and knowledge we’ve obtained through acquiring some of the best and brightest designs, and use that as a springboard to launch even better concepts. This issue is chock-full of examples of our creativity.

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CARRIER LUMBER A collaborative effor t reaped big gains for Carrier Lumber with its newly redesigned

SUBSCRIPTIONS Tel.: 250.833.3028 subscriptions@usnr.com EDITOR Colleen Schonheiter colleen.schonheiter@usnr.com

USNR Woodland, WA, USA: +1.360.225.8267 Mon. - Fri. 5:00 am - 5:00 pm PT

planer infeed line. USNR did the design and

24/7 Service: +1.360.225.8267

engineering, and manufactured the proprietary

info@usnr.com | www.usnr.com

pieces, and Carrier’s own exper t craftsmen turned out some of the more standard elements. The result is inspiring.

SÖDERHAMN ERIKSSON Söderhamn, Sweden: +46.270.746.00 Mariannelund Sweden: +46.496.218.00 Mon. - Fri. 07:30 - 16:30 CET

VIRTUAL LUG LOADER It’s no secret that USNR is a master inventor for its integration of new designs. Fresh off the drawing board is a new board feeder, our

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info@se-saws.com | www.se-saws.com

6th offering for this purpose, and likely the most unique and elegant design you could ever imagine. We call it the Vir tual Lug Loader, and we think you’ll love it!

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VISION TILT One of the benefits of the new cooperation between USNR and Söderhamn Eriksson is access to Vision Tilt. It is the only system on the market that monitors and controls your band saw per formance. It improves lumber size accuracy, minimizes wear on saws, wheels and guides, and lowers energy consumption. Check it out.

CARTER HOLT HARVEY Australia’s largest lumber producer recently installed a new debarking line at its facility at Morwell, Victoria. Front and center in the line is the Cambio 800 debarker, a workhorse that is ably turning out higher production with no increase in labor.

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© 2015, U.S. Natural Resources, Inc. All rights reserved. POSTMASTER: Send address changes to 1981 Schurman Way, Woodland, WA 98674. Canada Post: Return Undeliverable Canadian Addresses to: USNR c/o Colleen Schonheiter, 3550 - 45th Street Southeast, Salmon Arm, BC V1E 1X1


Carrier Lumber

Design fits the bill INNOVATION COMES FIRST FOR CARRIER’S NEW PLANER INFEED Over the years Carrier and USNR have developed a great cooperative relationship that has allowed both companies to innovate and thrive. This project at Carrier Lumber is a prime example of a great result that can come with a collaborative effort between vendor and customer. In early 2013 USNR was awarded the contract to install a worldclass planer infeed system at Carrier Lumber’s Tabor mill at Prince George, BC, to increase the throughput to match the speed of the planer. At the same time Carrier wanted to reduce downtime and the reliance on human intervention.

Working toward those same goals USNR had developed new technology that Carrier was eager to incorporate. The result is a planer infeed line that reflects inspired innovation, improving production significantly and reducing downtime, as well as the draw on resources.

Production has increased by approximately 15% and is continually rising. Downtime has dropped, and we no longer operate with a planer feeder.

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CARRIER LUMBER – DESIGN FITS THE BILL Carrier Lumber dates back to 1951, founded by William Kordyban Sr. Today the company is still privately owned by his son, Bill Kordyban. In 1976 the company built on its current location, called the Tabor mill. The Tabor complex currently comprises a two line dimension sawmill, planer mill, dry sheds, a wood yard, and dry kilns. The mill has continually upgraded its equipment to enable it to maintain its reputation for producing high quality lumber, yielding 1x4” through 2x12” in 8-20’ (2.5-6 m) lengths of J-grade, Stud, Premium 2&Btr, #3 and Economy. Logs are obtained through the mill’s timber licenses supplemented with private wood, and are hauled from up to a 150 mile radius. The mill processes Lodgepole pine and spruce logs with a 4” top and up to a 24” butt. Sawmill operations in the Carrier group include Carrier Forest Products at Big River, Saskatchewan, a reload facility at Prince Albert, Saskatchewan, and a strategic alliance with First Nations and a local community that have spawned Cheslatta Forest Products at Ootsa Lake, BC. The combined total annual output from the Tabor and Big River mills is in the range of 500 million board feet (1.2 million m3) of lumber. A significant story in its history, Carrier pioneered the development, manufacture and use of portable modular mills for fire and insect-killed salvage, all done in remote operations. Some of the equipment

in the company’s modern mill complexes at Tabor and Big River has been built with the portable mill concepts that Carrier Lumber developed at its own fabrication shop, touted to be the largest in Northern British Columbia.

Collaborative effor t Bill Kordyban explained that the primary purpose for the investment was to increase production at the planer. The new planer’s location was upstream from the old machine, and necessitated a relocation of the existing infeed equipment. Bill decided it made sense to build an entirely new infeed that would keep pace with the faster planer capacity. Bill continued, “We chose to work with USNR because we like to manufacture our own equipment and USNR was amenable to allowing us to manufacture much of it, while USNR produced those pieces of a proprietary nature. The infeed was therefore a collaboration between USNR and ourselves, which we always find very refreshing.”

Continuous Tilt Hoist The new planer infeed starts with USNR’s Continuous Tilt Hoist. The tilt hoist has evolved over time, with the latest design capable of unstacking up to 22 tiers of lumber per minute, depending on package size. This design incorporates linear transducers and servo valves, actuated

from the PLC, for continuous performance with no inhibitions based on environment (temperature, etc.). The Carrier system is designed for packages 5’-0” wide x 5’-0” high x 20’-5” long stickered, with packages stacked 2 high at the tilt hoist and dunnage between. Bill Kordyban commented, “The continuous tilt hoist increased our production and provides smooth operation.” Carrier also wanted to automate the stick/ dunnage collection process. The new system efficiently separates sticks from dunnage. Bill advised, “This is now almost automated. We still have an attendant monitoring, and we are working with USNR to completely automate this process.” (See following pages for details about the Continuous Tilt Hoist.)

Vir tual lug loader The Virtual Lug Loader (VLL) is downstream from the lugged let-down and storage tables. The VLL is a unique design with no overhead feeding apparatus; it is fitted with a series of belts that are progressively adjusted to separate, then feed the boards into lugs. The design speed for this installation is 200 LPM to accommodate future planer mill requirements. The VLL lug loader is setup to run each of the product widths at the optimum speed and timing to minimize user intervention.

NEW PLANER INFEED LINE MILLTRAK DUAL ARTICULATING GATE

BOARD TURNER

WANE SCANNER

LUG LOADER PRE-GAP TABLE

VIRTUAL LUG LOADER

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MILLTRAK

VIRTUAL LUG LOADER

The Virtual Lug Loader is controlled and monitored from above by the MillTrak lumber flow control system.

PATENTED

CONTINUOUS TILT HOIST LUGGED LET-DOWN

TILT HOIST INFEED CHAINS

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CARRIER LUMBER – DESIGN FITS THE BILL The new board turner design turns only the boards as determined by the scanner. Two sets of turner arms are mounted on alternate sides of the board turner chains, and each set of arms on the same side turns every second board. The turner arms move with the lug transfer so as not to inhibit the speed as boards are turned.

PATENT PENDING

The Continuous Tilt Hoist increased our production and provides smooth operation.

For the Carrier Lumber application, the VLL uses 4 sets of belts to accommodate the planer infeed layout and lumber recipe, and a single MillTrak sensor controls both the backlog and actuation of the belts. Bill is pleased with the operation of the VLL, “It needs no overhead feeding structures creating clutter, and operation is very smooth.” (See following pages for details about the VLL.)

Wane scanner, on-demand board turner The mill employed an older Newnes scan frame fitted with LPS geometric sensors to serve as a wane scanner. Bill said, “We wanted to orient the lumber “wane up” so any excess planing allowance would be removed from the waney face, which will result in a higher grade outturn.” A board turner assembly is situated immediately downstream from the wane scanner, and turns only the boards as determined by the scanner. Two sets of turner arms are mounted on alternate sides of the board turner chains, and

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each set of arms on the same side turns every second board (in effect, each board turning operation can be completed over 2 lug spaces to allow smoother operation). The turner arms move with the lug transfer so as not to inhibit the speed as boards are turned. Downstream from the board turner is a dual articulating smart gate that drops out boards with excessive bow, twist, crook or moisture (moisture measured via moisture meter located immediately downstream from the scan frame). The complete line features electric actuation with the exception of the smart gate that utilizes pneumatics, and the Continuous Tilt Hoist which uses hydraulics.

Meeting targets Bill reiterated that the goals for the new planer infeed line were increased production, smooth operation and labor savings. He commented, “Production has increased by approximately 15% and is continually rising. Downtime has dropped, and we no longer operate with a planer feeder.” He noted some of the challenges in the project were attributable to first-of technology like the VLL and board turner. He said, “This challenge was overcome by training, and persistent technicians working long hours and committing to improvement as the start-up progressed.”

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Watch the line in action: https://vimeo.com/ 127765968


The Virtual Lug Loader needs no overhead feeding structures creating clutter, and operation is very smooth. It is a gem to watch.

He also commented about the success of some key components in the line. “The Continuous Tilt Hoist works better and smoother than we anticipated.” He continued, “On the Virtual Lug Loader with MillTrak control, our technicians need to become better versed with it. It is a gem to watch.” As with any new system, training is essential to make the most of the technology and the investment. Bill commented that there was a steep learning curve with the new systems, but it is working out well. He gives credit to Aaron Parent, fabrication shop manager, and Dylan Tobin, plant manager, for making this project such a success. The Tabor mill is well positioned with a new front end to its planer line. Bill’s plans for the future include investments to automate further down the line and handle the increased production the planer mill is realizing with its new infeed. USNR’s collaboration with customers like Carrier Lumber is a huge win-win. Both vendor and customer benefit from the shared talent, expertise and commitment, and can take great pride in the result.

Pictured above, the new stick and dunnage collection system effectively separates sticks from dunnage and transports each into designated bunks via automated handling.

Top: Sticks exit the tilt hoist area onto a wide landing belt. Middle: From the landing belt the sticks drop onto the stick transfer chains, where they are transported to the stick bunks.

Bottom: Dunnage goes to the same wide landing belt, drops onto the same transfer chains, and a chain shear drops the pieces of dunnage onto a belt that transports them to the dunnage bunks.

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Virtual Lug Loader

PATENTED

Efficient design, less maintenance ELEGANT NEW CONCEPT OFFERS RELIABLE PERFORMANCE Developing new technology is a way of life at USNR. In a few shor t years we’ve introduced many new products, systems and processes to expand your capabilities. We’ve brought you new concepts like MyMill 1, PGLR 2, BioVision 3, THG 4 and BlockLogix 5, new scanning systems like MillTrak 6 and BioLuma 7,

innovative configurations like cut-n-two that don’t require empty lug spaces, and a host of others. In answer to our customers’ challenges we’re leading the industry at adapting new concepts. Now we’ve developed a unique lug loading design that is elegant and effective. We think you’ll love it!

1 2 3 4

5 - XY lathe charger scanning based on ControlLogix platform 6 - Automated material flow control 7 - Industry-leading sensor technology integrating geometric, vision, GrainMap™ grain angle measurement, and more

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Wireless mobile control, optimization Log turn correction and verification Transverse automated green mill grading Transverse automated dry mill grading

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The VLL lug loader can be setup to run each of the mill’s product widths at the optimum speed and timing to minimize user intervention. In a typical application two MillTrak sensors are mounted above the flow; the first controls the backlog to the VLL, and the second controls each successive sets of belts. The VLL operates at speeds up to 200 lugs/minute.

The design of the VLL looks deceptively simple. It uses the barest of mechanical apparatus to perform its task. With no cams, no cylinders, no overhead devices, lumber just flows seemingly effortlessly. Here’s why you’ll like it: Fewer

moving parts mean less maintenance is required

Far

less chance of jam-ups than with other designs

The first Virtual Lug Loader was installed at Carrier Lumber’s planer infeed area in early 2015, while interest in this new design is growing. The VLL is USNR’s sixth board feeder, joining its counterparts: ElectraTong, QuadCam, Revolver, Gatling and Newtronic. With so many designs in its kit, USNR has a machine that will suit any budget, product recipe and throughput requirement. Contact us to learn which one is best for you.

Reliable

production, no matter what your product mix

All

electric, no pneumatics

Better

line-of-sight with no overhead feeding apparatus

Watch the VLL in action: https://vimeo.com/ 127765968

Efficient

control via MillTrak mounted above the flow

HOW IT WORKS The first set of belts creates a gap by running faster than the chains on the upstream storage table. The second, third and, if required, fourth sets of belts (depending on product and application) successively correct the board’s skew. Each of these skew correction belts has its own motor for independent actuation, allowing the lug loader to straighten each of the skewed boards. The final set of belts (phasing belts) time the board to the lugged transfer, depositing each board into a separate lug. Immediately

upstream from the VLL, a backlog table is controlled via USNR’s MillTrak system, with a sensor mounted above the flow.

A

gapping table with beltways initiates the gap between boards.

Next

is the skew correction table #1, where each of the beltways is independently driven to facilitate skew correction.

Skew

correction tables #2 and 3 also utilize independently driven beltways to complete skew correction.

Finally

the phasing table sequences the boards to the speed of the lugged transfer, while feeding them into the lugs.

A

second MillTrak camera is mounted above the VLL to control the beltways for gapping, skew correction and phasing actuations .

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New Product Focus

Our newest addition to our lug loader lineup is the Virtual Lug Loader™ (VLL). VLL uses a system of belts in combination with our MillTrak lumber flow control to quickly and efficiently load boards into lugs. This allelectric board feeding solution is a unique design with no overhead feeding apparatus; a series of belts are progressively adjusted to separate, then feed the boards into lugs.


Continuous Tilt Hoist

Speed and agility NEW DESIGN UNSTACKS CONTINUOUS BLANKET OF BOARDS USNR’s Continuous Tilt Hoist has evolved over time, with this latest design capable of unstacking up to 22 tiers of lumber per minute, depending on package size. This concept incorporates linear transducers and servo valves, actuated from the PLC, for continuous per formance with no inhibitions based on environment (temperature, etc.).

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How it works A package advances to the tilt hoist and is loaded onto the primary hoist knees, then knees and frame tilt. Once fully tilted, the knees hoist the package until the top layer of lumber spills onto the lugged let down, and successive tiers continue to be indexed and spilled. When there is approximately 30 inches of package remaining on the primary hoist knees, the secondary hoist knees are extended into position via rack and pinion assemblies. Once into place, the secondary hoist takes over the indexing process from

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the primary hoist, continuing to spill the remaining tiers of lumber. Concurrently, the primary hoist lowers and returns to the upright position to accept the next package. Then the primary hoist tilts back and hoists up its load to just below the secondary hoist knees. When the secondary hoist has spilled its last tier, its knees will retract to allow the next package on the primary hoist knees to move up to the spill position. The secondary hoist frame will lower back to home position, ready for the next cycle. The


Design Improvement

handoff from primary hoist to secondary hoist is in the range of 3 to 5 seconds, allowing for nearly continuous unstacking of lumber. All hoisting and tilting is controlled with closed-loop feedback to servo valves from linear positioning transducers, resulting in precise and smooth control of the machine. USNR has sold 6 tilt hoists with this latest design that was released in 2011, and a conversion of an existing tilt hoist to this design. Tilt Hoist conversions, either an older style continuous or beam style hoist, can be readily performed depending on the design of the equipment and the existing structural building, to allow the new components to be pre-assembled and brought into the structure. Contact us to discuss your best options.

Above: The secondary hoist nears the end of its load, while the primary hoist ascends from below to take over the next cycle. Below: Frost thumpers are mounted to the tilt hoist frame to thump and separate the tiers of lumber from the load when frosty temperatures freeze the tiers together.

Watch the Continuous Tilt Hoist in action: https://vimeo.com/ 127765968

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Cut-N-Two Innovation

Cut-n-two boards merge into the flow, prior to entering the sorter.

No more skip-a-lug REVOLUTIONARY CONCEPT YIELDS BIG GAINS IN PRODUCTION When presented with a challenge our teams strive to come up with a solid solution that will not only resolve the issue, but go one better. Case in point is a new process for handling cut-n-two lumber that was implemented as par t of a recent project. Along with a new planer mill trim/sor t/stack line, USNR introduced

Cut-n-two / no skip-a-lug A conventional system demands that for every board that is cut-n-two, a lug space must be created to accept one half of the board. That requires the line to run faster to handle the additional boards that are produced. This new design allows the line to run at a consistent speed while cutting longer products.

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a cut-n-two configuration that does not require the need to skip a lug. This allows the mill to expand its range of products, put more wood in the sor ter without a throughput penalty, and without increasing planer speed or labor.

After the board is cut in half at the trimmer both halves remain in the same lug space. The far end half of the cut-n-two board is diverted up an elevator where it is even ended to the clear line. Meanwhile the near end board remains on the lower deck and even ended to the lumber line, it travels up an incline and the two boards are merged again into the same lug space at the top, just prior to entering the sorter.

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At the sorter, the clear line cut-n-two boards are diverted into the first sort bins along the clear line. All the full length boards and lumber line cut-n-two boards are diverted into downstream bins along the lumber line. Once the clear line cut-n-two boards reach the stacker infeed, a long rollcase shifts them to the stacker’s lumber line.


Process Innovation

Rethinking the process This configuration provides an opportunity for mills to make two short length boards from one lower value long length board, without sacrificing line speeds or throughput volumes. The improvements implemented at this mill removed significant bottlenecks, allowed it to expand its range of products, and reduce its operating hours. Other configurations similar to this concept have subsequently been developed, such as side-by-side or tandem bins where each half of a cut-n-two board goes into a tandem bin fitted with independent bin floors. Please contact us to discuss how we can reconfigure your lumber handling process to improve your line’s performance.

The unique cut-n-two handling is achieved by splitting the flow via an elevator (top right). Clear line boards are even ended at the top of the elevator (right). Lumber line boards are even ended to the lumber line and travel up an incline. Cut-n-two boards merge into the same lug space once again at the top (opposite page), prior to entering the sorter. At the sorter, the clear line cut-n-two boards are diverted into the first sort bins along the clear line. All the full length boards and lumber line cut-n-two boards are diverted into downstream bins along the lumber line (bottom right).

Watch the Cut-N-Two system in action: https://vimeo.com/76635698

NEW CONFIGURATION

TRIMMER

ELEVATOR

CLEAR LINE ENDING ROLLS

LUMBER LINE ENDING ROLLS

CUT-N-TWO ENDS MERGE

INCLINE

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Rörvik Timber The vision camera is mounted on the return side of the saw blade where it is protected by its enclosure, while it monitors the band saw blade in real time.

Vision Tilt: ultimate band saw control IMPROVED MEASUREMENT ACCURACY, REDUCED WEAR ON SAW BLADES, AVAILABLE WORLDWIDE There isn’t any equivalent to the Vision Tilt system being offered by any other supplier.

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Rörvik Timber in Myresjö, Sweden recently invested in an upgrade to its saw line. As par t of the project the company selected the Vision Tilt control system for its bandmill. Vision Tilt improves sawing accuracy and extends saw blade service life. The patent-pending

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Vision Tilt system controls saw blades by actively tilting the band wheels. It can easily be installed in new and already existing band saw lines, processing any species, in any region worldwide.


We are dependent on accurate measurements, and to achieve that the bandmill wheels have to be in exactly the right position.

Rörvik Timber is one of seven sawmills in the Rörvik Group. The sawmill has a staff of 55, working two shifts. Annual production amounts to approximately 140,000 m3 (60 mmbf) of sawn spruce products in larger dimensions. The mill also undertakes further timber processing in its large finger-jointing facility. Rörvik’s products are sold primarily to builders’ merchants in Scandinavia and Germany, where requests often come for exact cut lengths of up to 13 m (43 feet). Rörvik’s Production Manager, Tommy Halldin described the company’s reason for taking on the project. “We undertook a thorough evaluation of the entire sawmill and compiled a list of the main reasons for stoppages. We saw that there was great potential for improvement in this area. We are dependent on accurate measurements, and to achieve that the bandmill wheels have to be in exactly the right position.” After implementing the new Vision Tilt system on the bandmill, Tommy described the positive results. “Besides improved accuracy, the wheels are now subject to less wear and the saw blades last longer. We feel much more confident that we are getting accurate measurements. We have also

We already have several SE solutions in the sawmill, and we were looking for a supplier who could take total responsibility for the equipment in the entire sawline.

With the Vision Tilt system a cut-out section in the bandmill’s shrouding allows the vision camera access to monitor the saw blade.

improved our flaw detection in the saws, which gives us a great level of confidence. If a saw blade drops out, that can mean a big problem for the working environment, and serious damage to the equipment.” Tommy explained why Rörvik chose to work with Söderhamn Eriksson (SE) on this project. “We already have several SE solutions in the sawmill and we were looking for a supplier who could take total responsibility for the equipment in the entire sawline. We were confident Söderhamn Eriksson would be an excellent partner for us. We are also aware that there isn’t any equivalent to the Vision Tilt system being offered by any other supplier.” Efficiency is of vital importance to Rörvik. They recognize that competition is extremely tough, and raw materials are expensive. “It’s a matter of getting the best recovery from our raw logs and maximizing the efficiency of our production. We can’t afford not to be accurate. Vision Tilt contributes to both increased measurement accuracy and improved equipment life.”

Besides improved accuracy, the wheels are now subject to less wear and the saw blades last longer.

SE and Rorvik worked well together throughout the project, and have built a strong relationship. “Most of all, I appreciate having an open and wellfunctioning relationship that I feel is extremely valuable. We’re dependent on the assistance we are getting from Söderhamn Eriksson to be able to develop and make the improvements necessary to maintain and expand our position in the market for the future.”

Though the system had only been operating a short time, Tommy noted better value and volume recovery. “It’s too early to say, because we’re still in the running-in period. We are noticing, however, clear improvements when running at full speed.”

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RÖRVIK TIMBER – VISION TILT: ULTIMATE BAND SAW CONTROL

USER RECOGNITION “This is a very smart solution that feels safe and reliable in every respect.” – Jörgen Törnqvist, Älgsjö sawmill, Sweden

HOW VISION TILT CAN BENEFIT YOU Vision Tilt, developed by Söderhamn Eriksson, improves your lumber sizes as well as saw blade service life. The patent-pending Vision Tilt system controls saw blades by actively tilting the band wheels and can easily be installed in new and already existing band saw lines. It is available for processors in every region, processing any species, both hard and softwoods, worldwide, What makes Vision Tilt unique is that it detects deviations from the normal saw band position in real time and with very high accuracy. Using vision technology, it measures exactly how large the deviation is and triggers a signal that actuates the band wheel tilt to rectify the saw band position. The camera itself is placed behind a guard so that it cannot be damaged by saw band rupture or the like.

Improves lumber size accuracy Minimizes wear on saw bands, band

wheels and saw guides Reduces saw band rupture Lowers energy consumption Accuracy of measurement

corresponding to ± 0.5 mm Applicable for new and existing band

mills from any vendor, worldwide The equipment includes a vision camera sitting protected on the return side of the saw blade. Level with the upper band wheel’s center, the camera monitors the saw teeth position in relation to the band wheel’s front edge. Incorrectly aligned saw blades over time generate cracks in the tooth base as well as wear on band wheels and saw guides. Vision Tilt actively corrects the saw band’s position on the band wheel, which not only minimizes wear but also improves sawing accuracy. Besides the camera, Vision Tilt also includes a PLC with software for monitoring and adjustment. The surveillance images from all saws are displayed on one and the same screen for the operator’s visual information. The intelligent saw band control system alerts the operator to faults such as saw bands showing signs of imminent rupture.

This screen capture shows how the Vision Tilt camera monitors the saw teeth position in real time, and in relation to the band wheel’s front edge. Over time, incorrectly aligned saw blades will generate cracks in the tooth base as well as wear on band wheels and saw guides.

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Please contact us for more information about Vision Tilt and how it can benefit your bandmill process.


More options. More opportunities. The combined product line of USNR and Söderhamn Eriksson offers a wider variety of advanced sawmill solutions, giving you more options when it comes to planning a project. More options means more opportunities for you. Our expanded manufacturing capacity enables us to deliver more efficiently. You’ll soon discover the same experienced team you’ve come to count on is still designing, servicing, and supporting all of our products. Combining our resources and expertise creates a winning combination for USNR, Söderhamn Eriksson, and for you.

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Millwide. Worldwide.

www.usnr.com


Carter Holt Harvey

Cambio 800: Perfect fit INCREASED PRODUCTION, WITHOUT INCREASED LABOR

The machinery is so productive that we can skip extra shifts and overtime to meet our production targets.

Car ter Holt Harvey Ltd. is Australia’s largest group of producers and distributors of lumber with several production facilities in their home country. Now they have invested in a new debarking line from Söderhamn Eriksson for their saw mill in Morwell, Victoria.

We opted for Söderhamn Eriksson’s equipment because it is perfectly suited for our capacity and our mixture of species and log dimensions.

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Mark Bass, Greenmill Reliability and Plant Improvements Manager at Carter Holt Harvey Morwell, describes why they invested in the new Cambio 800 debarking line from Söderhamn Eriksson. “Our old equipment was worn out and about to give up,” he says. “Downtime periods got longer and longer, and maintenance costs skyrocketed. We opted for Söderhamn Eriksson’s equipment because it is perfectly suited for our capacity and our mixture of

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species and log dimensions. In addition, the line was easy to fit into our facility without necessitating major changes.” Carter Holt Harvey’s experience with equipment from Söderhamn Eriksson also comprises a merry-go-round saw line delivered earlier. “Their machines are reliable and built to last”, Mark Bass says, explaining why it was easy to opt for Söderhamn Eriksson once again. “The machinery is so productive that we can skip extra shifts and overtime


CAMBIO: IT GETS BETTER AND BETTER A team of design engineers whose sole mandate is to further develop our Cambio debarkers, assisted by fabricators and service technicians specializing in Cambio, comprise the experience and expertise behind the many recent improvements in Söderhamn Eriksson’s debarking lines. The aim is a smooth, continuous flow debarking line for optimum production and minimum maintenance.

to meet our production targets. This also makes it easy for our service people. As we have now increased production within a shorter period of time, we are able to shut down the line for scheduled service.” The installation was trouble-free, according to Mark Bass. He thinks the project was handled very well by all people concerned. “From the planning stage through installation, everybody cooperated to achieve the best possible results for Carter Holt Harvey. My impression of Söderhamn Eriksson and their employees’ competence and know-how is very good indeed.” With the new debarking line, the sawmill in Morwell has increased its production without increasing hours, decreased its overtime costs and gained time for scheduled maintenance. That’s how Mark Bass summarizes his company’s investment in Cambio 800.

Among the improvements most important for the customer is a feature making it possible to stop the debarker at any time, no matter where the log is,” explains Jonas Blomberg, Cambio product manager. He adds, “Modern processing lines rather avoid having a buffer of debarked logs between debarking and saw lines. This means that when the saw line stops, also the debarking line must be stopped. And this we have solved by making the debarking tools open up when feeding stops.” Debarking tools that automatically release the log are essential for continuous feeding without log gap, which increases capacity and is easy on the wood and the machinery. Debarking tools play a vital role in obtaining high-quality debarking where all the bark is stripped from the log without wood fibres following along. This is why our debarking tools undergo continuous development to ensure optimum results independent of changing seasonal conditions and raw material. Another important improvement that Jonas Blomberg is eager to point out are individual drives for each feed roller. Earlier models employed one motor with a chain transmission

driving all the rollers. “Our design is based on redundancy. This guarantees robust systems that operate independently and are resistant to jam ups and stoppages.” One more interesting feature is automatic control of the feedworks’ pre-opening mode. This is of great advantage when debarking unsorted logs, as it reduces strain on the machine while ensuring perfect log clamping. Two new infeed conveyors which allow for increased feed speeds, have also been developed. The new infeed conveyors are designed to facilitate the elimination of log gaps. Another example of product development for Cambio is a completely new debarking rotor that is being tested by one of our customers. “I would also like to tell you about our new, patent-pending feedwork tensioners with power transmission integrated into the feed roller linking system. This reduces strain on the machine frame,” says Jonas Blomberg. And last but not least, the Cambio team is working on comprehensive improvements for the work environment. The machines should be easy to service, and it should be clean and pleasant to work inside a debarking facility.

Cambio debarkers are available in every region, processing any species, both hard and softwoods, worldwide, Please contact us to learn more about our signature Cambio debarkers.

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PGLR Rotation Correction

Making every turn count LOG TURNING DESIGNED FOR MAXIMUM RECOVERY USNR has made great advancements to improve scanning and positioning of the log for initial breakdown. USNR’s Precision Geometric Log Rotation (PGLR) system is a key example. The PGLR system monitors and corrects the log rotation process in real time, and increases recovery by reducing log rotation error.

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The PGLR scanning system is located at the log turner machine section. Four SmartTriCam 3D sensors scan the log as it is being rotated. The actual log rotation path is compared to the autorotation optimizer’s projected log rotation path to generate log rotation corrections. The log rotation corrections are transmitted to the PLC for correction of the log rotation path on-the-fly as it continues through the log turner. Log rotation error is typically reduced by 50% or more.

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PGLR can compensate for log turning errors due to the following: Mechanical Feed

wear

speed changes during the turn

Irregularly Transfers

from one conveyor to next

Interaction Slippage

shaped and crooked logs

with pressrolls

and hesitations


One mill’s experience An installation at a mill in the Southeast US is proof positive that the PGLR system delivers impressive payback. Griffin Lumber Company at Cordele, Georgia is a family-owned operation. The mill processes Southern Yellow Pine logs from 5-24” diameters and 8-16’ (2.5-5m) long. Finished lumber ranges from 1x4” to 2x12”, but the vast majority of the mill’s production goes to 5/4 x 4” and 5/4 x 6” decking. The operator feeds logs onto the autorotation vee-flight chain where it is first scanned with Smart TriCam sensors in a dual zone orientation, and the scanned image is sent to the MillExpert log rotation optimizer. The optimizer analyzes the image for sweep, and if the log exceeds a certain sweep threshold it is turned horns down. If the log is within the sweep threshold it is turned for best value.

The cant remains on the sharp chain and is scanned by a single zone Smart TriCam scanner, and the cant image is sent to the System Quality Inspector (SQI) which provides QC analysis information for the mill. The cant exits the sharp chain onto an outfeed deck that feeds the gangsaw.

Recognizing the value Jesse Griffin said they chose USNR for several reasons. “We know USNR can optimize a log better than anyone out there, and start-ups have always gone flawlessly.” The Griffin team was clear about the significance of accurate log rotation, particularly on logs that need to be turned horns down for sweep. Because of their rising sharp chain arrangement they realized the importance of having two points of contact on the sharp chain on logs with lots of sweep. This could only be guaranteed with a PGLR system that would ensure the log was being rotated correctly.

and 19 out of 20 were off 3.19 degrees and 18 out of 20 were off 2.84 degrees. We also only lost 0.375% of the volume from the initial scan to the final solution scanner. I don’t think anyone can argue against those kinds of numbers.” Jesse continued,“It is a real testament to the whole system when you can scan a log, rotate it, impale it on the sharp chain, send it through the chip heads and saws, and the log only moves 3 degrees. That really shocked me when the results started coming in.” He continued, “We’ve seen enormous uplift in productivity and yield. We are very satisfied.” To read the full story, go to: www.usnr.com/Griffin-PGLR.pdf. To learn how PGLR can improve your recovery, please contact us.

The final performance test numbers tell the story. Jesse explained, “We ran 20 logs,

Then the log passes through the PGLR sensors and is scanned as it is travels through the turners. The PGLR provides continuous feedback to the PLC about the orientation of the log to correct the log’s rotation on-the-fly and achieve the target turn angle. After it has passed through the turners the log travels on a short flighted chain with centering rolls. The log is impaled on a very unique rising sharp chain. This setup is extremely efficient as the log does not need to be thumped onto the chain. The log travels through two more scan zones and the scanned image is sent to the MillExpert canter optimizer to generate the best value solution. The log optimizer has a turn detect component that analyzes the actual orientation of the log and provides feedback regarding the accuracy of the turn.

The turn detector compares images of the log before and after the turner to measure the actual turn error on every log.

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Product Focus

We’ve seen enormous uplift in productivity and yield. We are very satisfied.

The log travels through a side chipper\quad bandmill arrangement where opening faces are revealed, and sideboards are sawn off and sent to an outfeed that feeds the edger.


New Projects Boise Cascade – Core Drive The Boise Cascade plant at Chester, SC is investing in a new Core Drive for its lathe. The Model 1380 Core Drive unit will minimize deflection of the block, allowing it to be peeled to very small diameters and thus improving recovery. The new technology also substantially reduces spinouts at the chucks due to splits or soft ends in the block. This unit is designed to peel blocks in the range of 5” to 36” diameter.

Car ter Holt Harvey – Lineal Edger Opt. Upgrade

Battle Lumber – Trimmer Optimization System

Blue Nor th Forest Products – Trimmer Optimization Upgrade

The Battle Lumber mill at Wadley, Georgia is investing in a new Trimmer optimization system for its new tie mill operation. The system comprises a new scan frame outfitted with BioLuma 2900L HD laser profile sensors, and the MillExpert optimization platform.

The Blue North mill at Kamiah, Idaho is upgrading its Newnes Sawmill Suite Trimmer optimization system to the latest software version release, V7.2. This version release features improvements to some of the features including random width logic enhancements, shift rotation setup, operator assisted trim for grade, bow recovery for multi-board pieces, and more.

The optimizer will improve recovery and increase uptime with simplified calibrations, improved diagnostics, and supportable hardware. The Trimmer optimizer supports linear positioner or stacked cylinder positioning fences and smart tipple configurations including trim/ save, cut-n-two and trim/reman.

Bennett Lumber – Gang Optimization Upgrade The Bennett Lumber operation at Princeton, Idaho is upgrading its Gang optimization system with MillExpert optimization paired with BioLuma 2900LX HD laser profile scanning. The PLC system will also be upgraded to the ControlLogix platform. Training for the new technology will be provided at USNR’s Woodland, WA facility.

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Carter Holt Harvey at Hazelwood, Australia is upgrading its Newnes Sawmill Suite Edger optimization platform to the latest version release, V7.2. This new version improves Edger solution diagnostics, features Edger repositioning with risk analysis, full Trimmer decision logic, tailer setup to improve throughput, and more. Also part of the project, the obsolete Hydra sensors will be replaced with LPL sensors, and modifications to the scan frame will accommodate the new sensors.

EACOM Timber – Planer Mill Equipment The EACOM Timber Timmins, ON mill is modernizing its trimmer line with a new Revolver Lug Loader and Multi-Track Fence.

Boise Cascade – Veneer Dryer

Groupe Savoie – Horizontal Twin Bandmill

Boise Cascade at Florien, LA has ordered a 6-deck, 21 section gas-steam Veneer Dryer. The new dryer will feature the Automatic Dryer Exhaust Control (ADEC) system and Cooler Pressure Balance Control that together are proven to reduce:

Groupe Savoie is investing in a 63” Horizontal Twin Bandmill Resaw for its plant at Saint-Quentin, NB. The equipment is scheduled to be started in early 2016.

thermal energy cost volume of dryer exhaust to be processed fugitive emissions at front of dryer hydrocarbon build up at front of dryer production labor cost

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Hood Industries – Counter-Flow Kiln & Repanel Hood Industries at Waynesboro, Mississippi will install a new Counter-Flow Dry Kiln with Kiln Boss control system. The company is also investing in a new roof, walls and gable end panels for an existing double track, steel framed dry kiln. The new panels will be pre-fabricated to 3” thickness utilizing the USNR panel design.


Maibec – Log Sor ter Optimizer

Tulsa SA – Lathe Core Drive

This Saint-Pamphile, Quebec operation is upgrading its log sorting process with USNR’s MillExpert Log Sorter Optimizer system. The system will allow scanned logs to be sorted based on pattern, full breakdown solution, or geometric features including length, diameters, ovality, taper, sweep and surface variability.

The Tulsa SA veneer plant located at Lota, Chile has ordered a new M1396 core drive for its veneer lathe. This design will minimize deflection of the block as it is peeled to very small diameters. It substantially reduces spin-outs at the chucks that can occur with splits or soft ends of the block. This powered core drive design permits peeling incoming blocks from 5” to 36” in diameter, and takes advantage of diminishing block sizes to aid in usable veneer recovery.

Rex Lumber – Edger Optimization Upgrade The Rex Lumber operation at Brookhaven, Mississippi is upgrading its transverse Edger optimization system with BioLuma 2900L laser profile sensors paired with MillExpert optimization. The MillExpert Edger Optimizer supports almost any machine type including traditional sideloading edgers to high-speed lineal systems with multiple scan zones.

Spanish Trail Lumber – Revolver Lug Loader Spanish Trail Lumber has ordered a Revolver Lug Loader for its sawmill at Marianna, Florida.

Versowood Group – CamShift 600 The Versowood Group is Finland’s largest privately owned wood processing group with a total annual production of some 1.3 million m3 lumber. For its sawmill in Otava, Versowood has ordered a debarking line from Söderhamn Eriksson. The line includes a modular-designed CamShift 600 debarker with a pull-out rotor and separate feedworks.

Western Forest Products – Headrig Carriage Optimization The Western Forest Products mill at Nanaimo, BC will upgrade its process with new carriage scanning and optimization. The system will feature MillExpert carriage optimization paired with LASAR2 3D sensors, for both front and back side scanning. MillExpert optimization software has been installed very successfully in both softwood and hardwood carriage applications. Up to 300 degrees of log coverage can be achieved by adding back side scanning to the basic front side scanning system. Seeing the whole log allows for more accurate product fits on the front and back side of the log, which in turn leads to better recovery. Additionally, the back side scanner can be used as a backup for the front side scanner in case of a scanner failure.

The CamShift 600 debarks at feed speeds up to 130 m/min with one debarking rotor and features a log-releasing tool function as well as tool pressure adjustment during operation. The equipment is to be shipped from Söderhamn Eriksson’s manufacturing unit at Söderhamn, Sweden in midDecember 2015.

COMPLIMENTARY SUBSCRIPTION For your complimentary subscription to USNR’s Millwide Insider magazine e-mail subscriptions@usnr.com or go to www.usnr.com/about/news

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PO Box 310 Woodland, WA 98674

Millwide Insider is printed on recycled paper.

Profile Christian Winlöf is Sales and Marketing Director for the Söderhamn Eriksson division, based at Söderhamn, Sweden. Christian has worked for Söderhamn Eriksson (SE) for nearly 10 years, with experience in capital sales in a variety of geographical regions. In his current role he is responsible for managing the capital sales activities for the SE product lines world wide. He recalls a few major projects he has been involved with, “The first sawline I sold in 2004 stands out in my mind, a Super Saver

UPCOMING EVENTS

line in north Sweden. Another was the new line installed at SETRA, Nyby Sawmill with the Eurosaw S6D, a new design at the time.” Christian says he most enjoys interacting with customers all over the world, helping to improve their mills’ outcomes. He also appreciates his management role that affords him the opportunity to impact the SE organization to remain a top producer. With his free time, Christian enjoys spending time with family, and golfing and boating in the summer, and hockey, skiing and snowmobiling in the long, dark Swedish winters.

NOV. 24–27 WOODEX

DEC. 2 OptiSaw

FEB. 2–4 IHLA

Moscow, Russia

Montreal, Quebec

Indianapolis, Indiana

MAR. 9–11 HMA

MAR. 22–24 Wood Convention

APR. 6–8 COFI

Fort Worth, Texas

Montreal, Quebec

Kelowna, British Columbia