Sorting system – Kallfass

Sortierung Seitenware, sorting side products, chargement de produit lateral

Bis auf den letzten Millimeter ausgenutzt EN Utilised down to the last millimetre

Åsljunga Pallen from Örkelljunga in southern Sweden specialises in the manufacture of pallets and packaging goods. The company produces around 7500 pallets a day. The sawn timber required for this comes from their own sawmill. Around 60,000 m3 of sawn timber is produced there every year, 99% of which is processed in-house. “This makes us one of the largest pallet manufacturers in Sweden”, reports Stefan Nilsson, owner and managing director of Åsljunga Pallen. The pallets are sold to customers in Sweden and Denmark within a radius of around 300 kilometres.

Best solution offered

Sorting the side goods was the bottleneck in production. “The quality control was done manually - that was very time-consuming”, explains Oscar Elzén, Production Manager at Åsljunga Pallen. For this reason, the decision was made to invest in a new sorting and stacking line from Kallfass, Baiersbronn-Klosterreichenbach/DE. As part of these conversion measures, the company also expanded its sawing line to include a resawing machine from EWD. "This means that it is now possible to cut the entire log to size for our pallet production”, the production manager continues.

“Kallfass understood how we work and which process is best for our plant, and offered a technical solution for our requirements that we liked”, explains Nilsson, who is the third generation of his family to run the company.

Space and time - two challenges

The building in which the new sorting and stacking facility is housed dates back to 1956. This has recently been expanded somewhat. “However, we had to make do with the available space for this extensive project and utilise every millimetre”, explains Dominik Hauser, who supervised the project on behalf of Kallfass, with a grin: “During installation, there were even bets as to whether the robot would actually have enough space for its intended function without having to make any adjustments to the building. To the detriment of some sceptics, however, the robot was commissioned as planned”. He is referring to the robot that is responsible for automatically filling the moulding magazine. But more on that later.

In addition to the available space, there were other points to consider: Initially, a large part of the installation was carried out during ongoing operations. “We only had six weeks of downtime”, Elzén informs us. And the roof must not be opened during installation. “Thanks to the cooperation of everyone and the high level of flexibility on the part of Kallfass, we were also able to master this”, says Nilsson and is very satisfied with the mechanisation specialist's handling. Assembly began in March and the sorting system for the main and side products has been in operation since the beginning of August.

Complex mechanisation

Kallfass supplied the mechanisation with transverse take-off, rising diagonal conveyor as well as cycle-in and thickness measurement between the existing sawing line and the new EWD resawing machine. “Before the resaw, there is the option of transporting the main product to an existing stacking system via an automatic take-off device, depending on the dimensions, output, adjustment or maintenance work on the main line”, explains Hauser. In addition to a direct side product infeed, a stock edger is located under the new main product infeed to the resaw, which also feeds the boards for sorting. Each of the three feeders has its own buffer level. “The main goods are buffered on one deck and the side goods on two decks. When a floor is full, it is emptied automatically so that the sawing line does not come to a standstill”, Hauser explains. A level changer takes the boards to the top. The goods are first aligned there before the Tongloader cycles them into the carrier conveyor at a rate of up to 120 parts per minute. There is also the option to cut back at zero line.

After another level change downwards, a Microtec scanner recognises the wanes and gives each board the corresponding quality or dimension. These are then placed in one of the 15 vertical boxes. The boxes are emptied downwards onto a chain conveyor, which transports the box contents further onto a traversing chain conveyor feeding the timber to the parallel stacking system. “This solution was also due to the space available”, says Hauser. A step separator and an unscrambler transfer the boards to another cross conveyor for layer formation. The Kallfass project manager estimates their output at up to 14 layers per minute. The downstream multiple cross-cut saw from Kallfass is equipped with four saw aggregates - three of which can be positioned automatically. The layers of boards are then transported to the stacking machine, which has six magazines with automatic strip placing.

High degree of automation

The robot mentioned above fills the stick magazines. Kallfass installed an automatic feeding system for this purpose. A forklift driver places the stanchions filled with sticks onto a conveyor, from where they are fed into the system. Two different types of sticks can be fed separately via a hoisting unit. After the stanchions are emptied, the sticks are fed to the scanner via a step separator and unscrambler. The scanner checks the timber for dimensions and damage. Unsuitable sticks can be automatically ejected. This is followed by the formation of bundles, so the robot can grip several strips at once and fill the magazines. Kallfass also supplied the automatic pallet feeder for the stacking system. The number of pallets required can be determined according to the length of the timber. The empty pallets are automatically removed from the magazine and pre-positioned so that the pallet is always in the centre of the workpiece length. The layers of boards are then automatically stacked on pallets. The maximum stacking height including pallet is 1.9 m. Hauser specifies a target output of up to 90 packages per day.

Neues Sortierwerk überzeugte mit Technik EN New sorting system impressed through technology

After a fire in 2020 at the headquarters in Moussey/FR, the owners of the Lemaire sawmill decided to rebuild the line with a log band saw while investing in a new sawmill for cutting small diameter timber at the La Petite-Raon site a few kilometres away. "This step means we can process the entire log spectrum from the forest", says Managing Director Maxence Lemaire, explaining the move. They bought an industrial site in La Petite-Raon in 2006 which they previously used for sorting logs and operation of a planing unit. Installation of the saw line began two years ago. The sawmill was to be initially housed in the existing hall. However, the Lemaire family eventually decided to erect a new building. The log infeed came from Holtec, the cutting line was supplied by Veisto and Kallfass from Baiersbronn-Klosterreichenbach/DE was chosen for the sorting and stacking plant. "We looked at several providers. Kallfass impressed us both in terms of the technical execution and the expertise of the employees", explained Lemaire, adding that "Kallfass is also active in further processing and has already supplied us with a bundling system for the planing line". Kallfass handled the project with its French representative, VBI from Barr/FR.

Main and side products via a single line

The first log passed over the new saw line, which processes logs up to 55 cm in diameter, in September 2022. Larger dimensions are sent to the large diameter timber mill in Moussey. "Our goal is to cut 300,000 solid cubic metres per annum at both locations in the future. About 20 % of the volume involves large diameter timber", explains the Managing Director. All the main and side products produced on the new chipper line are conveyed separately on two decks to the Kallfass system. "The sorting and stacking system is designed for an output of up to 140 cycles per minute, lengths of 2 to 6.2 m and cross sections up to a maximum of 100 by 250 mm", relates Kallfass Managing Director Hans Haist.

New type of flexible alignment

The timber is conveyed via a transverse buffer conveyor and a separation station to an assessment station where an employee checks the material and pulls the pieces forward for a subsequent trimming if necessary. The boards and squared timber then pass through a Goldeneye 900 scanner from Microtec. This determines the quality and dimension, transmitting the data on to the subsequent Kallfass trimmer. Kallfass installed a novelty between the Goldeneye and trimmer: a flexible alignment. "This can adjust the boards - depending on the scan result - by up to 300 mm with centimetre precision. This means that shorter cuts can also be made on the end faces, ultimately increasing the yield", explains Haist. The trimmer is equipped with 13 saws. The timber is then divided into 71 sorting boxes.

After the boxes have been emptied, the wood is fed to another employee for a follow-up check via a step feeder and separator. Following the creation of layers, the timber pass through the tried and trusted multiple circular cross-cut saw from Kallfass. This saw is equipped with four sawing units, three of which are completely automated and can be positioned as required. Remaining pieces are discharged via a waste belt in the direction of the Vecoplan disposal unit. "The downstream stacking line has a capacity of up to 14 layers per minute and is equipped with six double magazines for stacking", elaborates Jonathan Bleesz from VBI. The finished packages, which are mainly 600 mm high, are sent to the Fromm strapping unit. Kallfass supplied a squared timber milling machine for this purpose. As mentioned at the beginning, the Kallfass plant sorts main and side products. However, space for another side product sorting unit was already taken into consideration in the conceptual design.

Lemaire is convinced that investing in the new sawmill was the right step: "We have already been able to win four large customers who previously imported sawn timber. Now we can generate added value domestically".

Etagensortierung von Kallfass, tray sorter of Kallfass

Produktivität und Effizienz gesteigert EN Added productivity and efficiency

Charles Ransford & Son is located in Bishops Castle—about an hour and a half’s drive west of Birmingham, England—where, among other things, the company focuses on manufacturing fencing and landscaping products for the domestic market. In its in-house sawmill, where Douglas fir, larch and spruce are processed, the company’s 58 employees produce around 55,000 m3 of sawn timber. The company has invested more than €22 million in further development in recent years. In 2022, two projects—a layer sorting system for long cross-sections and a post-pointing system—were successfully completed when the system specialist Kallfass from Baiersbronn in Germany, was commissioned. “When we made the investments, we first and foremost wanted to add to our productivity, not necessarily our volume”, explains Craig Leitch, Purchasing Director at Ransford. “Having the two new Kallfass systems, we can now respond more quickly to orders, improving our customer service in today’s challenging market. In addition, we have been able to add a seven-fold increase in our production output”, adds James Davies, Mechanical Engineer at Ransford.

A confident, long-standing partner

Ransford and Kallfass enjoy a partnership that goes back a long time: the first Kallfass stacking line was purchased 26 years ago. Ten years later, a box sorting system followed, which is still in operation today. “Kallfass is a very reliable partner who delivers the best technology available on the market. And when it comes to customer support, Kallfass is outstanding. The first discussions for the post-pointing system—a fully automatic fence production system—started in 2018. “The sale and planning then coincided exactly with the start of the COVID-19 pandemic. Due to Ransford’s confidence in our technology, we were able to handle the signing process exclusively online via team meetings”, Matthias Link, responsible for sales at Kallfass, explains the challenges.

New tray sorter

Upstream of the post-pointing plant, is Kallfass’s new sorting system, which has been in operation since October 2022. This system is specially designed for thicker cross-sections, measuring up to 200 by 200 mm and lengths of 1.8 to 4.8 m for gate posts or wooden sleepers. “Until now, we have been implementing the stacking of these systems by hand, requiring an enormous effort. When the new Kallfass tray sorter line is installed, we have taken another important step towards increasing productivity”, says Leitch.

The saw line made by EWD GmbH separates the squared timber and transfers the parts to the Kallfass roller conveyor at a speed of 120 m/min. Workpieces longer than 5 m or unsuitable can be discharged into a green chain. Subsequently, a curved conveyor transports the good parts to the new sorting system. After aligning the timber, an employee assesses the quality of the workpieces and rejects those pieces displaying unsuitable qualities. The measurement is carried out in a crosswise pass. Based on the measurement data, pivoting conveyors are used to place the timber on one of the four levels.

Immediately after emptying of the workpieces, the Kallfass automated system creates the layers. These layers enter the multiple cross-cut saw, equipped with zero-cut and two variable saws. The subsequent stacking uses five magazines where the sticks are placed automatically. Next, the system forms bundles with a cross-section measuring up to 1.2 by 1.2 m. The bundles then leave the hoisting unit, and a roller conveyor transports the bundles to the strapping unit. Here, a stacker picks them up and moves them to the post-pointing unit.

Significantly reduced manual handling

Previously, several employees were required to do the work; now, the post-pointing line takes over this process. “Today, however, only one operator is needed to complete the task“, explains Alex Cooper, the responsible engineer at Ransford. The post-pointing line processes wood cross-sections of up to 200 by 200 mm and post lengths ranging from 1.5 to 3 m.

Inside the new system, the packages are first destacked in layers, and the sticks are automatically stripped. Next, the operator assesses the lumber’s quality and uses a piece of chalk to mark any piece of timber that does not meet the required qualities. The identified parts can be automatically ejected later in the process. In the longitudinal pass, the squared timber enters the incisor (a device for scoring the wood, ensuring better penetration of the impregnating agent). Subsequently, automatic zero-point alignment takes place upstream of the post-pointing station. Finally, in the cross-cutting station, circular saws with a maximum cutting depth of 200 mm point the posts on all four sides while the timber rotates 90° automatically between saws.

Alternatively, the squared timber can also be processed using a radius milling cutting station instead of the circular saws. The squared timber is aligned beforehand and fixed in place using clamps. Two profiling units mill the rounding in synchronous and counter-rotation and thus ensure uniform processing without fraying of the posts. “The milling station has a capacity of up to six pieces per minute”, Link explains. The downstream Kallfass stacking system stacks sawn posts in single or multiple lengths, and places the sticks automatically. According to Link, the system has an output of up to five layers per minute. For Ransford, the clean packages, in particular, are also a definite benefit compared to the past: “The beautiful appearance of the uniform stacks makes a much better impression on the customer”, confirms Leitch.

Flexibilität auf eine neue Ebene gehoben EN Flexibility raised to a new level

The distinctive feature of the planing line and quality sorting line starts with the package feed. In order to achieve this, Kallfass used a two-level design. “At the lower level, the packages are transported in a straight line, moving towards the laminated timber production system. A long roller conveyor moves the wood from the upper level to the tilt destacker”, explains Enrico Goldhahn, Kallfass’ Project Manager. The packages are separated in layers, and the stacking strips are automatically collected. During the transport, the boards are guided to a pre-separator which then passes the boards on to the unscrambler. A thickness measurement device is integrated into the latter. If two pieces of wood are placed on top of each other, both pieces are ejected and returned to the unscrambling trough. The aim is to keep all manual operations as low as possible. After alignment at the zero line, a TongLoader® unit separates the board film. Goldhahn puts the TongLoader’s® output at a maximum of 80 boards per minute.

All measurements are taken during the transverse run-through

While the lumber follows the transverse run-through, it also passes the Mesutronic metal detector and a face cutter, which prepares the lumber for the subsequent strength measurement process. Microtec also supplied the M3 Scan moisture meter, the Optiside cup scanner and annual ring detection system, the Curvescan 3D board shape scanner, and the Viscan strength grader. All measurements take place during the run-through process. The Optiside scanner transmits a signal to the downstream Kallfass turning device, prompting it to rotate the lumber. Workpieces that do not meet the specified criteria are rejected.

Planing or quality sorting

At this point, the paths diverge: If a pure quality sorting operation is selected, a bypass is used to convey the good lumber past and beyond the REX planing machine at a speed of up to 400 m/min.
Variant 2: The good parts requiring planing are fed into the Kallfass planing machine, where an acceleration conveyor optimises the infeed of the timber. Goldhahn indicates that the intake system can reach up to 80 cycles per minute. The feed speed of the planing system can reach up to 350 m/min. Behind the planer, a conveyor belt advances the boards to the Microtec Goldeneye. The entire intake, scanning, and outfeed areas can be shifted to the left out of the planing line or to the right into the bypass line. If scanning is not selected, a motor pushes a bypass belt into the line instead of the scanner. After scanning, the parts move into the marking station, which can also be pushed into the line. Slowdown belts transfer the parts to the roof-top chain conveyor. “Here, the parts can come either from the bypass or the planing line – never from both lines at the same time”, Goldhahn explains.

At the sorting station, an operator arranges the boards according to three quality levels. He advances the pieces manually—one piece at a time—onto the assessment chain conveyor. A ram infeed unit transfers the goods (80 pieces per minute) to the infeed conveyor of the level sorting unit. In this area, the widths and thickness are measured. In addition, three Lumi scanners read the applied marking and the control system compares the marking with the scan result. After that, they part ways again.

Bundling systems at a height of 6 m above the level sorter

Only workpieces that have been split in the planing machine and are narrower than 70 mm, as well as profiled boards, enter the Kallfass bundling system. The latter is installed 6 m above the level sorting unit. The sticks are labelled on an ascending belt conveyor before an aligning roller conveyor adjusts the sticks at the zero line. A motor-driven, height-adjustable gantry for applying labels is fitted with two labelling devices. Kallfass automatically assembles the sticks into bundles and straps them together. “We delivered six bundling units—so there is less adjusting required”, explains Goldhahn. Another labelling unit for the finished bundles is installed in the outfeed area.

All other boards enter one of Kallfass' six sorting levels. “Depending on the dimension, a package may have to be separated and placed on two levels. Because of the existing structural constraints, we had to proceed with this option”, Goldhahn explains. A pivoting conveyor is used to empty the individual levels. These boards are labelled as they pass through the production line.

Once the filling level has been reached, the levels are emptied, and the layers are formed. The boards pass through the Kallfass multiple cross-cut saw with five sawing units. The shortest cutting length is 800 mm. “The pivoting saws are equipped with tandem cylinders. This allows us to vary the cutting height up to 160 mm. In addition, the zero saw can be adjusted by 500 mm”, explains Kallfass’ project manager.

Subsequently, the stacking takes place. The machine is equipped with eight stick magazines. In order to achieve greater stability for the ongoing transport, the Kallfass system can also stack the boards diagonally. For lower packages, an auxiliary hoisting unit with swivel forks increases the capacity.

The wood packages intended for the subsequent production of glue-laminated timber are fed directly into this production area using a roller conveyor. A forklift truck can be used to remove packages halfway along the line. At the end of the roller conveyor, an automatic crane made by Voith automatically removes the packages. Shipping packages are moved to the right-hand side and below the stacker. Here, a height-adjustable film dispenser automatically places the film on the stack first. The Kallfass mechanical system transfers the stack to the strapping unit, which includes a packaging press and applies four edge protectors to the stack. Squared timbers are then placed on the package. The roller conveyor is partitioned into three sections so that strapping and placing the squared timber can take place simultaneously. Finally, the wood packages can be stacked by the downstream stacker. “As an alternative to foil wrapping or strapping, there is a bypass that is integrated inside a foiling tunnel. In order to use this option, the packages are deflected to the left-hand side downstream of the stacker”, explains Goldhahn.

This is the third installation

Kallfass already delivered a smaller planing line for Cordes in 2018, which was completely rebuilt in 2020 and upgraded in order to include a bundling system. The assembly of the large-scale project described here started in 2021. Since 2022, the processes have been gradually improved and optimised. “We delivered approximately 65 lorries containing system components to Bremerhaven in order to construct the new quality-sorting and planing facility”, says Goldhahn, describing the overall scale of the project. The system can process lengths ranging from 2 to 6.2 m, widths of 75 to 310 mm and 16 to 125 mm thicknesses.

Ausbau des Sortierwerks EN Expansion of the sorting system

The family-run Bois Du Dauphine is located in the Alpine region between Grenoble and Chambéry, France. Founded in 1983, the company was originally a forestry operation. In the meantime, a timber industry has developed in Le Cheylas, France: B.D.D. operates a sawmill, and the neighbouring sister company A.E.B. produces pellets, heat, and electricity. In keeping with the saying, “stagnation is regression”, those people responsible have devised a sensible investment strategy for 2022 to 2024. The objectives are clearly defined:

Increase in cutting capacity by approx. 25 %
Improving the yield by 3 % based on more accurate defect detection, precise cuts, and sorting in several boxes when the length is distributed from 2.5 to 6 m in 50 cm increments
Additional increase in yield to be achieved by doubling the number of side products
Increasing the capacity in the pellet plant and stabilising power generation in the winter season

New sorting system in operation

In September of 2022, B.D.D. was able to complete one of these investment steps: Kallfass, Baiersbronn, Germany, installed and expanded the sorting system, including the wood package and strapping system.

First, Microtec installed at B.D.D. a Goldeneye scanner to replace an existing one. When using the downstream trimmer saw, which was subsequently installed by Kallfass, undesirable wood features can be effectively removed. Thereafter, the sorting takes place: In the past, B.D.D. separated all sawn timber (main and side products) using 25 sorting boxes. In order to expand the system, Kallfass added 50 more inclined boxes. According to Kallfass, the charging system can output 160 pieces per minute. The board cross-sections range from 12 x 60 mm to 100 x 250 mm, whilst the lengths vary from 2.4 to 6 m.

The boxes are emptied downwards onto a long buffer chain conveyor. After the boards have been separated, they pass in layers through a multiple cross-cut saw with seven saw aggregates.

Flexible stacking

Subsequently, the boards are transferred to the stacking unit, where 16 layers per minute can be produced. B.D.D. opted for the Kallfass stick placement system, which comprises seven adjustable double magazines. This design allows thin sticks (14 x 25 mm)—that were previously intended to be disposed of—or thicker kiln sticks (25 x 50 mm) to be used.

“Now, this system allows us to produce different packages”, explains Bertrand Jurdic, Technical Manager at B.D.D. The package sizes range in width, height and length from 1,000 x 450 x 900 mm to 1,200 x 1,400 x 6,000 mm.

The finished packages enter a swivelling package discharge system, which changes from the transverse to the longitudinal direction. The strapping station, made by Fromm System GmbH, is supported by a layer of squared timber. In addition, Kallfass will supply an extended aligning roller conveyor, thus increasing the buffer area.

Little downtime

Kallfass completed the modification effort in the summer, requiring about three and a half months. “We only required three weeks of downtime for the saw line during this time, in order to connect the new sorting system to the existing plant from 2010”, Jurdic explained. Kallfass delivered the steel and mechanical parts for the project using 13 lorries. B.D.D. decided to use a wooden construction method for the new hall.

The entire preliminary discussions, consultation, development, and handling of the project were organised by Hans Haist, Managing Director of Kallfass when he interacted with Jonathan Bleesz of VBI (Kallfass' representative in France). “When we expanded the sorting system, we were able to achieve an important step in our expansion plans”, says Jurdic.

Sortierwerk kann trocken und nass EN Sorting system for wet and dry

Mostovdrev is a joint stock company and one of the largest wood processing enterprises in the Republic of Belarus. In addition to being sold in Belarus, its furniture, construction and finishing products are also exported to the CIS countries, Europe and the Middle East. Mostovdrev is firmly committed to strict quality control and use of the latest production technology. For this reason, the company decided to expand its sawmill through the addition of a new combination timber sorting system with connected stacking plant from Kallfass. Installation was completed last year, followed by commissioning of the plant. Mostovdrev’s declared production target is to process 100,000 m³ per annum.

Transparent processes in the sorting system

Both dry timber and fresh wood from spruce and pine are processed at the Mosty location in two shifts. The main product and side boards are received from the EWD saw line and fed to different buffer conveyors for unscrambling. Alternatively, the dried or damp product can also be fed to the unscrambler via a tilt destacking system. A package chain conveyor upstream of the tilt destacking system buffers up to 3 packages (with sizes of 1.5 x 1.5 and 1.2 x 1.2 m). The separated timber is backed up and cycled onto an assessment chain conveyor for manual quality control. Each board is individually accommodated and rotated for inspection on both sides before being deposited again on the conveyor. A worker examines the product and can realise chop cuts by pulling waney timbers a little from the conveyor. Product dimensions are subsequently checked and classified before forwarding to the sorting system. Mostovdrev has chosen a compact sorting system with 20 vertical boxes and a box for non-assignable pieces that can be filled with timber lengths of 2,000 to 6,200 mm at a rate of 60 cycles/min. Sorting programs and Kallfass visualisation software facilitate management and enhance the transparency of processes in the sorting system. Fault messages and board data can be archived and recorded.

Stacking with automated stick placement

In order to stack the sorted timber, the first 5 sorting system boxes are first emptied contrary to the conveying direction onto a conveyor and, only then, conveyed further in the conveying direction to avoid tilting of timbers. The batch then needs to be unscrambled before layers can be created with widths between 1,200 mm for shipping packages and 1,500 mm for drying packages. The downstream Kallfass multiple cross-cut saw is equipped with 4 freely adjustable saw units and cuts the trimmed product precisely in layers to desired lengths (shortest crosscut length 1,200 mm). Stored cutting programs facilitate quick batch changes where necessary.

Individual layers can be stacked in the stacker in single or multiple layers of packages with a maximum width of 1,500 mm. Placement forks then pick up the individual cut layers and place them on the package to be formed. Placement of drying sticks between each layer is automated and realised at a defined distance with 12 stick magazines. Dispatch sticks are laid manually. Finally, the completed packages with a maximum length of 6,000 mm are marked with a label and strapped to increase stability.

Zuführung Schnittholz aus Sägelinie, feeding timber from saw line

Flexible Sortierung EN Flexible sorting

A fire on 30 May 2020 destroyed the sorting system at the Sägewerk Kolb sawmill, Ruppertshofen/ DE. Speedy intervention by the fire brigade and a sprinkler system prevented flames from spreading to the sawing facility and surrounding buildings. However, the sorting system was completely destroyed, but a decision to rebuild it was made immediately. Although the new sorting and stacking plant was rebuilt as before in the same location, completion was delayed due to construction regulations. The new sorting system in the Sägewerk Kolb sawmill was commissioned around 14 months later during the summer this year.

The best concept

The choice of a supplier for the new plant fell on Kallfass, the mechanisation specialist from Baiersbronn-Klosterreichenbach/ DE. “Naturally enough, we took a look at different suppliers, but Kallfass offered us the best concept”, related Wolfgang Kolb, justifying the decision he reached together with his son, Fabian Kolb. One aspect appealed in particular to the pair. “Kallfass was the only supplier to develop a combined solution for the main product and side product, being in fact the only one to come up with the idea. Together with the close proximity to Baiersbronn and the excellent reputation Kallfass enjoys, the latter was the decisive factor”, explained Kolb.

No worker needed for the side products

Kallfass delivered a complete sorting system to Kolb, with 75 boxes, a stacking system and a connection to the sawmill. During a tour of the facility, Kallfass Managing Director Hans Haist pointed out the separating unit behind the board edger. “Depending on the sawing pattern, up to five boards positioned closely next to each other can be delivered to the existing cross conveyor. We integrated a further separating unit in this area by installing a single feed unit in the sawmill, ensuring continuous and uninterrupted transport down the line”. The side products from the board edger are conveyed to the upper deck of the sorting system via a conveyor belt. They continue their journey from a curved conveyor to a cross conveyor towards the boxes. Feeding on a carrier chain continues in this area, and the length, width and thickness is measured. This data is used for box classification. The boards then continue their journey into one of the 75 boxes. “What’s special here is that, in principle, the side boards are sorted without worker intervention. A worker assessing the product and, in effect, standing one floor lower can intervene in the process if necessary”, explained Kallfass Project Manager Dominik Hauser. This means that the entire plant can be operated with just one worker.

Kallfass installed its reliable inclined boxes at Kolb. “The advantage of this is that – due to a filling level control – the boards only have a minimum drop height and, as a consequence, fewer breakages occur”, explained Haist. “Also, a box can now hold almost twice the previous volume”, added Fabian Kolb. A box that has been suitably filled is then discharged downwards. The journey to the assessment station continues via a longitudinal conveyor and unscrambler. Where necessary, the worker can eject boards with waney edges or of unsuitable quality downwards though a flap. The layers of boards then pass through the tried and trusted multiple cross-cut saw from Kallfass. This is equipped with a zero line and three variable saw aggregates. Finally, the layers are transferred to the stacking systems through automated stick placement, with the completed packages travelling downwards and being strapped manually by the forklift operator. The installation of an automated strapping system is planned in this area.

Stacking of the main product is also automated

As mentioned at the outset, Kolb can also move main products of up to 6 m in length on the new Kallfass plant. These travel from the circular re-saw on a conveyor belt to the sorting system on the lower floor. They move from here through a separating unit to the worker and complete the same journey as the side products through the multiple cross-cut saw and layer formation to the stacker. “Moving the side boards and part of the main product over the same system gives us enormous flexibility”, emphasised Wolfgang Kolb.

The new Kallfass plant is designed for lengths of 2.5 to 6 m and side products with a thickness of 18 to 100 mm. When stacking the main product, Haist estimates the thickness to be 120 mm. The sorting system is designed for an output of up to 50 cycles per minute, while the stacker can complete up to ten layers each minute. Kallfass installed the control cabinets and electronics in a container which was delivered to Kolb as a turnkey unit. The supplier also delivered the entire control system. The layout of the sawmill, with the plant on two sides of a stream, led Kallfass to construct the new sorting and stacking system 0.5 m higher. The walls of the sawmill, constructed with cross-laminated timber (CLT), are also at the same distance from the floor. “There are also no motors in this area, so the plant can begin operating quickly again following any flooding”, explains Haist.

Schmuckstück:
Neues Schwachholzsägewerk EN An Absolute Jewel:
New Small Diameter Sawmill

The main product, predominantly lamellas for glulam timer, is intended for the supply of glulam plants. Side boards which cannot be processed are supplied to packaging customers. “In future, the sawmill will reduce purchasing considerably for both companies in Wunsiedel and Weißenstadt. However, 100 % self-sufficiency is not possible”, explains Küspert. Wunsiedel primarily proved attractive as a location because GELO Timber had in WUN Bioenergie a pellet producer and cogeneration plant operator as a neighbour. But WUN Bioenergie is not just any neighbour: Küspert is co-initiator of the energy park and, additionally, a shareholder and Managing Director. This creates attractive synergies with, in essence, sawmill waste being exchanged for electricity and heat. Küspert calls the sawmill the “Smart solution 4.0”.

An enormous feat

Construction commenced in Wunsiedel in December 2019. An already tight schedule was adhered to, despite the Corona pandemic, and the first trunk was fed through the saw line a year later in December 2020. “It was an enormous challenge for everyone involved, but we were able to commission the plant within the given time”, says the Managing Director, and he is proud of how successful this cooperation has been. A second shift was already launched a few weeks ago. The sawmill has been designed for an annual output of 350,000 solid cubic metres in two shifts. “That may not seem a lot at first glance, but more than 18 million linear metres of logs need to pass through the plant every year to achieve this output. Our sawmill in Weißenstadt, where we process larger diameters, is only handling 4 million linear metres for an output of 250,000 m³/per annum”, relates Küspert. The Wunsiedel sawmill is intended for thin-end diameters of 8 to 25 cm and a timber length of 2.5 to 5.3 m.

Clean sorting

Main and side boards are conveyed via a tilt destacker onto two separate decks towards the sorting and stacking system from Kallfass in Klosterreichenbach/DE. The mechanisation specialist also installed an automated stick feeder. The main and side boards are fed through an unscrambler onto a curved conveyor. The worker assesses the timbers on the downstream conveyor. If a face section is necessary, he pulls the board up to 0.5 m from the conveyor. During the visit, Kallfass Project Manager Matthias Link pointed out the rollers that make handling of even heavy boards extremely easy.

Single feeding with a TongLoader towards the wane scanner and trimmer occurs in the transverse run-through. The TongLoader grips each piece in a manner similar to a hand, separates the board film, singulating and feeding it into the next conveyor. The significant advantage of the TongLoader is that it can also handle different timber dimensions, piece by piece. Link indicates that the Kallfass sorting system output is up to 120 cycles per minute.

A Microtec scanner determines the dimension and detects the wane. The Variosort sorting control system assigns each board an appropriate box number and information for the downstream Kallfass trimmer. The latter has seven saw blades and can also be used for destructive cuts. “The operator can also indicate additional characteristics for boards through colour marking, indicating conditions such as beetle damage, blue stain or rot”, explains Link.

Boxes up to 30 % larger

GELO Timber decided to pick 40 inclined boxes. In order to reduce stacking on the premises, the Kallfass system can stack packages with a width of up to 1.65 m and a height of 2 m. These dimensions also facilitate best possible exploitation of the Valutec continuous kiln. Kallfass created larger inclined boxes than usual for this reason. “The boxes are around 30 % larger”, says the Kallfass Project Manager.

Full boxes are emptied downwards onto a cross conveyor and separated by a step separator. Kallfass also installed the re-sorting system for kiln packages above the cross conveyor, with one kiln package making up to two or three shipping packages. These are separated in layers through tilt destacking. The stacking sticks fall automatically onto a conveyor belt and are collected separately.

A worker can even assess the quality of both damp and kiln timber again if necessary, or reject undesired pieces. Subsequent to this, the Kallfass mechanisation system creates the layers according to the package specification, and these are conveyed through the Kallfass multiple cross-cut saw. This is equipped with a zero line and four variable saw aggregates. Placement forks then transfer the completed layers to the stacking system. Stacking output is up to twelve layers per minute.

The Kallfass stacking system is equipped with eight double magazines for kiln and dispatch sticks. Kiln sticks are 1.6 m long, while dispatch sticks have a length of 1.2 m. Strip laying is automatic. Finished packages are lowered using a paternoster lift. Damp material is conveyed from there to the Valutec continuous kiln opposite. Shipping packages are conveyed to a Fromm strapping station which Kallfass has retrofitted with an automated feeding system for squared timbers.

As initially mentioned, Kallfass also provided the automated stick feeder for kiln and dispatch sticks. The feeder was automated to cope with the volume of kiln sticks required. Stick bundles are transferred to a cross conveyor and separated. A scanner checks the dimensions and detects damage to sticks such as knotholes and splitting. Unsuitable sticks can be ejected downwards through a flap. Following scanning, the sticks are collected and bundled with ten sticks per bundle. Dispatch sticks are provided using a manually charged belt conveyor. A robot grips the stick packages, filling the stacker magazines with them. The major advantage of this solution is the option to position the magazines variably and still fill them automatically.

Successful project

Complete administration of the sawmill is handled by GELO in Weißenstadt. This enabled them to keep personnel figures low in Wunsiedel. “We currently have 32 personnel working in two shifts. The sawmill can be operated by a mere eleven people during each shift. We wanted to build an absolute jewel – and we’ve succeeded in this in every respect. All the solutions involved were implemented exactly as we imagined. The new sawmill means we are well equipped to face the future”, says Küspert. He is particularly proud of the overall concept involving the neighbouring pellet and cogeneration plant – “It’s a location advantage that nobody can take away from you”.

The complete investment involved EUR 38.5 million. The sawmill location covers an area of 11 ha, 7 of which are presently in use. Küspert also has a few pleasant ideas regarding the rest of the location. “But first, our main focus will be on the new sawmill”, concluded the Managing Director.

Flexibilität auf eine neue Ebene gehoben EN Flexibility raised to a new level

Hegener-Hachmann Sawmill

The 12 October 2019 saw commissioning of the new sawmill at Hegener-Hachmann. This involved probably the most flexible production processes every realised in a medium-sized sawmill enterprise, posing a planning and technical challenge to all involved.

“Hanxleden 4.0 online sawmill – innovative, resource-efficient sawmill concept for SME” was the project title of the approx. € 11 million investment made by Hegener-Hachmann, Schmallenberg/DE. The new construction took exactly a year from October 2018 to October 2019. After a further twelve months, the planned cutting volume has, in terms of figures, been achieved – but right from the outset.

Exploiting as many resources as possible

Hubertus Hegener-Hachmann heads the company in what is now the fourth generation. He receives significant support in this role from Markus von Weichs who, as his business partner, is primarily responsible for purchasing logs. Having started as a forestry business with an originally small sawmill as a sideline, Hegener-Hachmann had a used head saw and a circular saw when he invested in the first expansion in 2007. “We decided in favour of a completely new construction to ensure the sustainability of our business and, insofar as possible, to be able to cut a broad variety of log types, including in part from our own forestry. Among other things, this enabled us to continue production independently at the location during the production phase. Our goal is to ensure careful and effective use of the resources used during the entire production process”, says Hegener-Hachmann. “We want to process everything at a single location. As a medium-sized enterprise, we can only continue to exist on a broad basis”. What he means by this is not only classic sawn timber such as the raw material for solid structural timber, construction timber or landscaping timber. Hegener-Hachmann is well known in the region for his solid wooden flooring consisting of hard and softwood that goes by the name of “Gutshofdiele”. Larch, Douglas fir and Norway spruce are also processed.

As the entire endeavour is regarded as somewhat of a supra-regional flagship project in terms of flexibility, efficiency and conservation of resources, it received ERDF funding from the Ministry for Environment, Agriculture, Conservation and Consumer Protection of the State of North Rhine-Westphalia as part of the “Ressource NRW” call for projects. This covered 50 % of the components eligible for funding.

What has been created is a modern sawmill with a planned annual cutting capacity of at least 40,000 m³ for soft and hardwood. This has proven highly complex in terms of the processes involved. When it came to the cutting technology, Hegener-Hachmann chose an inclined log bandsaw with a chipper-canter for logs up to 10.5 m in length and with a diameter of 1.3 m. Around 70 % of the timber comes online from the log yard for cutting without presorting. Hegener-Hachmann placed his trust in the know-how of Kallfass (in Baiersbronn, Germany) when it came to mechanisation and the sorting and stacking system. “Aside from the economic viability of the investment, what was decisive for us was the supplier we placed our faith in to accompany us on this journey. The Kallfass solution also impressed us very much, and the company gave us a commitment to realise the project within the estimated time” reasoned Hegener-Hachmann. “Online cutting and the wide variation in product dimensions posed major challenges for us”, remembers Kallfass Managing Director Hans Haist. Kallfass also provided the control unit for the sorting system. “The demanding timbers and varied dimensions meant our programmers were faced with a difficult task“, explains Haist.

A lot of things are possible

The log is in all cases precut on the bandsaw and, following trimming, conveyed on to the Combimes BNK and/or head saw in the Kallfass sorting and stacking plant. However, two other options are also available: “Products with a length exceeding 6 m and a thickness of more than 105 mm, blocks or individual high-quality pieces can be conveyed into special discharge 1 on the head saw or special discharge 2 behind the BNK. These can then be lowered with care to the lower level using a hoisting unit”, explains Hegener-Hachmann.

50 boxes and multiple occupancy

Timbers with a thickness of up to 105 mm, a width of 300 mm and a length of 6 m are fed into the Kallfass sorting system at Hegener-Hachmann. 50 inclined boxes are available here. With inclined boxes, the timber slides down more gently onto the chain conveyor during emptying. This is primarily an advantage where hardwood is involved. “Due to the enormous diversity of our products and the numerous wood types involved, the computer frequently assigns three different types to a single box if necessary”, says Hegener-Hachmann. In this case, the box is emptied when the filling level is reached and the dimensions which are not required are fed once again over a return run and sorted anew.

The timbers to be stacked are separated and assessed again by a worker with regard to quality in the transverse run-through. Inappropriate workpieces can be ejected or shortened here again. The boards are then fed through the Kallfass CNC multiple circular cross-cut saw. This cuts the timbers with zero and four variable saws, depending on requirements. “Cutting is perfect and realised with millimetre accuracy”, confirms the operator. This is followed by layer formation and packet assembly. Haist estimates the output to be up to ten layers or 60 boards a minute during cycling in. The packing system is equipped with eight magazines with automatic stick placement.

Finished packages are lowered using a hoisting unit. Space conditions mean that they are deposited on a roller conveyor located on one side. This pivots the package (which is on rails) through 90°. The package is then strapped and prepared for shipping. Half packages or packages that need to be unpacked without sticks after drying can be picked again using the connected tilt stacker during a renewed passage through the stacking plant.

Both the Hegener-Hachmann sawmill and Kallfass confirm their satisfaction with implementation and commissioning. The focus now is on ensuring together the continuous improvement of in-house processes and the data flow.

Produktion verdoppelt EN Production has been doubled

Claude Schnepf, Managing Director of SCS, employs 70 personnel, 40 of which are working directly at the sawmill in the Alsatian commune of Steinbourg/FR. SCS generates an annual turnover of € 22 million. Schnepf’s goal is to reach € 30 million per annum, which is why he decided to double the capacity of his existing plant. Construction of the plant and conversion of the premises cost around € 10 million.

Scierie et Caisserie de Steinbourg (SCS) is one of the largest beech wood sawmills in France. It began life as a sawline consisting of a log bandsaw from the French manufacturer Rennepont, a Techrnan mechanization system and a trimmer. There was no automated sorting system. The beech wood is dried and dampened (steamed) using twelve fresh air/exhaust air dryers from Mühlböck, and there are plans to add a further five. The original line produced 50,000 m³ p.a. of high-quality beech timber for furniture manufacture, squared timber and wood for pallet production. 80 % of products are exported to China, Asia, the Levant region, Spain, Italy and Germany. A number of reasons led Claude Schnepf to choose Kallfass as a partner for this major project.

The two most important were the geographical proximity (the Kallfass plant is only about 100km away) and linguistic commonality. “Kallfass played a leading role in the planning and realisation of my new sawline, and our cooperation worked perfectly”, stressed Claude Schnepf.

The project was completed at an impressive speed. The planning phase started in autumn 2016, with the new line commencing operation in the summer of 2018.

Doubling capacity

The new line consists of a Primultini log bandsaw, with the mechanization, sorting and stacking systems being supplied by Kallfass. The trimmer was provided by EWD, with a multi-blade circular saw being supplied by Primultini.

The part of the plant provided by Kallfass commences downstream of the EWD trimmer. The trimmed timber is conveyed through the contactless measurement system by a cross conveyor. The dimension measurement system from Kallfass measures the thickness and width using a laser/encoder and length with a safety light barrier. Quality is assessed with the aid of chalk markings and luminescence sensors. The beech timber is then classified in thirteen levels. The customer can individualise sorting as required.

Simplified variation options

When a box is filled, it is forwarded automatically to the packet assembly station, with stacking selectively possible using wooden or aluminium battens. The batten magazine is equipped with an automatic stick placement system. The completed packets can be collected by a forklift truck through a packet discharge on the outer wall.

“We configured the entire Kallfass plant with great care to avoid any damage to the high-quality timber involved”, explains Hans Haist, CEO of Kallfass.

Everything for pallets

Timber that does not meet quality criteria for furniture manufacture (e.g. squared timber with red heartwood) is cut to the desired length on a separate line using the Kallfass CNC crosscutting saw. The CNC crosscutting saw has four chop saws, enabling cutting of square timber with millimetre accuracy. Crosscut lengths ranging from 800 to maximum 3200 mm can be achieved. The capped square timbers are automatically forwarded downstream to the multi-blade circular saw for separation.

Training for employees

The second complete sawline has enabled SCS to double its capacity. Full exploitation of the machinery is only possible with training of additional personnel. Four employees working in two-shift operation are currently responsible for two band saws.

At least one additional machine is planned. Four employees are also working on the trimmer, with another worker currently undergoing training. “This completely new increase in production capacity is of little use to me without competent machine operators. We’re trying to give our current workers effective instruction while training new personnel to assist us”, adds Claude Schnepf.

Best solution offered

Space and time - two challenges

To make optimum use of the space, the Kallfass concept has several level changes.

“Kallfass understood our processes and offered us the best technical solution. We anticipate an increase in production of at least 20%”.

Complex mechanisation

View of the feeding of the main product to the resaw machine.

High degree of automation

Kallfass supplied an automatic stick feeding system to ensure a high degree of automation …

... and a robot for filling the magazines of the stacking system.

Feeding the side material to the wane scanner.

Visual assessment of the goods before the multiple cross-cut saw.

The side material is unscrambled, cut and then stacked.

Three years ago, the Lemaire sawmill decided to invest in another sawmill for small diameter timber. This means that the entire log spectrum can now be processed. Kallfass was chosen for the sorting and stacking plant, as the mechanisation specialist impressed in many respects.

Excellent cooperation: Lemaire Project Manager Antoine Glé, Kallfass Managing Director Hans Haist, Lemaire Managing Director Maxence Lemaire, Lemaire Production Manager Anthony Receveur and Kallfass representative Jonathan Bleesz (from left)

Main and side products via a single line

New type of flexible alignment

Installed for the first time: The flexible alignment in front of the trimmer saw can compensate for up to 300 mm.

The trimmer saw from Kallfass has 13 chop saws arranged in a 50 cm grid.

„Kallfass impressed us in terms of technology. The cooperation has been impeccable.“

Main and side products are divided into 71 boxes. There is still room for another sorting unit next to it should this be necessary.

The multiple cross-cut saw from Kallfass is equipped with four sawing units, three of which can be positioned automatically.

The stacking unit has six double magazines and a capacity of up to 14 layers per minute.

The 600 mm high wood packs which are stacked with the Kallfass system are typical for France.

A confident, long-standing partner

Charles Ransford & Son from Bishops Castle, England, specialises in the manufacture of fence posts, among other things.

Around 30% of the sawn goods produced are sorted using the layer sorting system —the cross-section at Ransford ranges up to 200 by 200 mm.

The tried-and-tested multiple cross-cut saw from Kallfass cuts the timber to the required length before it is stacked.

In the Kallfass post-pointing line, four circular saws “point” the posts in a cross-cutting cycle – after each saw, the post is rotated 90°.

New tray sorter

Significantly reduced manual handling

Last year, Kallfass delivered two systems to Charles Ransford & Son: at the end of October 2022, the sorting system with four levels went into operation; before that, the system specialist had already installed a post-pointing system.

In addition, Kallfass installed a milling station in the fence production system when a profiling unit was installed for circular milling of the squared timber.

For Ransford, an added bonus of the post-point system: neatly stacked parcels.

In May 2022, Cordes Holz of Bremerhaven, Germany, started a new planing line. The company relies on the expertise of Kallfass, Baiersbronn, Germany, for the line’s automation. In fact, skill was in high demand: The planing line is highly flexible, increasing its complexity simultaneously.

All measurements are taken during the transverse run-through

Mesutronic metal detector

Planing or quality sorting

Kallfass level sorter

Bundling systems at a height of 6 m above the level sorter

The Kallfass bundling station, 6 m above the level sorter

This is the third installation

Starting the Kallfass system: Package infeed and subsequent tilt destacking

Downstream of the TongLoader®, an employee assesses the product...

…before it passes through the Mesutronic metal detector

Kallfass intake into the planing machine; capacity: up to 80 cycles a minute

View of the Microtec Goldeneye and the Rex planing machine

The Kallfass bundling station, 6 m above the level sorter

Tried and tested: The multiple cross-cut saw made by Kallfass

In order to achieve greater stability, the boards can also be stacked diagonally

Expansion of the sorting system as part of the big investment plan

Pleased with the successful expansion of the sorting system made possible by Kallfass: Bertrand Jurdic (Technical Manager), sawmill manager Sylvain Mangournet, and Frédéric Hiegel (conversion project manager) at B.D.D. (from left to right)

New sorting system in operation

The sawn timber is now sorted according to length and cross-section in 75 inclined boxes – previously B.D.D. sorted the main and side products in 25 boxes

Flexible stacking

For its stacking system, B.D.D. opted for seven double stick magazines from Kallfass

Little downtime

Kallfass also supplied B.D.D. with the tried-and-tested multiple cross-cut saw with seven saw aggregates

The sawn timber is now sorted according to length and cross-section in 75 inclined boxes – previously B.D.D. sorted the main and side products in 25 boxes

The Goldeneye-Mircotec detects undesirable wood defects, ...

... which the downstream Kallfass trimmer saw cuts out with appropriate accuracy

For its stacking system, B.D.D. opted for seven double stick magazines from Kallfass

Sorting and stacking of dry timber and fresh wood in a single plant. Mostovdrev in Belarus has invested around EUR 2.5 million in an automated Kallfass sorting system.

Kallfass timber sorting system with 20 vertical boxes and a box for non-assignable pieces

Stick magazines for automated placement of dry sticks on stacking layers

Classification of timber prior to sorting through quality assessment with an assessment chain conveyor (rear) and dimension measurement system (front)

Charging of vertical box sorting system at 60 cycles/min.

Emptying of boxes onto a discharge conveyor, with the first 5 boxes contrary to the conveying direction to avoid tilting

Unscrambling of batches following emptying for subsequent formation of layers

The Kallfass multiple cross-cut saw cuts timber in layers to desired lengths

Stick magazines for automated placement of dry sticks on stacking layers

The sorting plant at the Sägewerk Kolb sawmill needed to be rebuilt following a fire. The sophisticated concept involved prompted Wolfgang and Fabian Kolb to choose Kallfass as a supplier.

Infeeding from the saw line: Side products on the upper level, travel towards the boxes, while the main product travels below towards the stacking system.

„Kallfass was the only supplier to offer us a combined solution for the main product and side product.“

The length, width and thickness of the side product and smaller main product dimensions are measured …

… and then assigned to one of the 75 inclined boxes.

Infeeding from the saw line: Side products on the upper level, travel towards the boxes.

Hans Haist (l.) and Dominik Hauser (r.) with Wolfgang (2nd from left) and Fabian Kolb in the sorting system.

The multiple cross-cut saw from Kallfass enables final trimming of the main product and side products before the timber enters the stacking system.

Kallfass designed the new sorting and stacking plant for both the main product …

… and side products. The worker can eject unsuitable timbers downwards through a flap.