Largest contract in company’s history
Since the purchase of the Fermoy/IE location in 1998 by the Smurfit Group, the Glennon Brothers have gradually expanded the sawmill with further processing facilities. The most recent addition was an extensive sorting and stacking unit with a planing machine.
The Kallfass, Baiersbronn-Klosterreichenbach/DE machine works is responsible for the former. The planing machine was delivered by Ledinek, Maribor/Sl. “It is probably the biggest contract we have ever handled,” said the Kallfass project manager Ernst Hauser. The Glennon Brothers operate a Linck line in Fermoy. The cut goods arrive in the drying chamber and then move to the new Kallfass sorting and stacking unit. Freshly-cut pallet boards can also be transported on this line, which has been in operation for approximately two months.
Synchronised piece by piece: Separation of the layers depending on package assignment, with two straightening steps
The forklift operator places the dried packages or the freshly-incised stacks of pallet boards on a package chain conveyor. There is room for five to six packages. The ESG destacking device separates the goods into layers. “This allows the stacking pallets to be automatically separated on a conveyor belt and then collected in carts,” explained Hauser. Since the unit allows for the transportation of double packages, squared timber can also be sorted with this facility (see image at the bottom of page 31). The work pieces pass through two separating stages along the chain conveyor. They straighten the wood and bring it to a zero line by means of an alignment roller conveyor. Both pieces of equipment are set for wood lengths of 2.4 m to 6.6 m. According to the mechanical engineer from Baden-Württemberg, the sorting plant processes 140 pieces per minute. The entry thickness of the work pieces is between 15 mm and 100 mm, the width between 75 mm and 300 mm.
Setting the course After separation, there are two different procedures depending on the product: The dried wood takes a direct route to an acceleration table in front of the motor grader. The pallet boards go in a different direction to the dried goods. The dried goods are first accelerated to up to 600 m/min and directed through a scanner (PLC stress grader).
-The sawn timber is adjusted to a zero line (r), then it moves into the planing machine.
This detects the wood characteristics and defines the quality on the basis of the criteria provided. In addition, the scanner determines the dimensions of the wood (length, width, strength). From there, the pieces move to the Kallfass sorting plant via roof chain conveyors and accumulating conveyors. A tong loader synchronises the sawn timber feed. Then, a reader recognises the work pieces from the stress grader and assigns them a corresponding box in the sorting plant. The sorting plant, with 20 raising and lowering boxes, follows the trimmer with five saw units at intervals of 300 mm.
-Trimmer capacitor (arrow), after which the evaluated sawn timber arrives at one of the 20 raising and lowering boxes
If one box reaches capacity, it is emptied downwards. The waste is separated before the goods arrive at the Ledinek planing machine. The equalized boards then arrive at stacking line 1. The sawn timber is directed lengthways through the Kallfass multiple cross-cut saw, which has been equipped with six saw units by the mechanical engineer following a request by the client. As necessitated by the goods produced by the Glennon Brothers (garden timber), the circular saws can be pivoted (by 28°). They can then diagonally trim the front face as required.Next comes the stacking machine.
-Feed to one of the two crosscutting systems, followed by packaging
It is equipped with automatic slat stacking, where the individual magazines can be motorically moved. When packaging is completed, a lifting mechanism transports the package to strapping. “The machine recognises the package size using light cabinets and automatically positions itself based upon the dimensions. This means that there are no delays and the number of bindings per minute increases,” reported Hauser. If required by the order, the packages can be foiled. The strapping machine is a Fromm product, the foiling machine is a Kallfass in-house construction. The finished packages are transported on the package chain conveyor under the sorting plant across to package removal, and are fed in via the raising roller conveyor with long rollers.
-After packaging (in the background) departure for one of the two strapping stations (front)
The next sequence The pallet boards follow a different production process. They are synchronised onto a belt conveyor by a level changer and are directed back towards sorting by the zip-merge loading procedure. On the basis of their dimensions (length/width/strength), these parts are then also directed to the sorting plant and assigned to individual boxes. After the roof chain conveyor, it is possible to discharge bad or broken goods. Layer formation then takes place, followed by another multiple cross-cut saw, which is structurally identical to the other: it also has six saw units and the circular saw blades can be pivoted by 28°. After stacking, a lifting mechanism transports the packages to ground level. A second machine is available for stacking. “If required, these packages can also be foiled,” explained the Kallfass project manager.
-Collection area: The stacking pallets and squared timber are automatically separated if in double packages and collected outside the hall