Sorting system – Kallfass

Bereits die vierte Anlage EN Already the fourth system

With three different sawing lines at the Saint Avit site, Dubot Bois & Scieries cuts 140,000 m3/year - exclusively softwood. One speciality is the cutting of Douglas fir, which accounts for around 50% of the total volume. “When using the three saw lines—from circular saw technology to log band saws—we can process almost all log diameters harvested from the forest”, explains Florian Baudron, the Technical Director at the sawmill. Logs with a diameter of 10 to 100 cm and trunks 2 to 9.5 m long are cut.

Enhanced performance and superior quality

The origins of the company date back to the beginning of the 19th century. The sawmill at the Saint Avit site has existed since 1945. Since then the Dubot family has continuously expanded the plant.

As mentioned at the beginning, Kallfass has been a supplier of sorting and stacking lines for a quarter of a century. Last year, Dubot ordered its fourth system from Kallfass. “Our system behind the circular saw line—also from Kallfass, of course—was becoming outdated. We also only had twelve boxes for sorting, which limited the performance of the saw line. For this reason, we decided to invest in a new sorting and stacking system”, reports Baudron and continues: “We also knew that Kallfass would be able to rebuild the new main product line in place of the old one”. As part of the project, Kallfass also supplied a wane scanner and a trimmer provided by Microtec. Both ensure that Dubot can produce a high quality of sawn timber.

The conversion at Dubot started in June 2024, and the Kallfass system has been in operation since the end of October. In the meantime, Dubot was able to transport the main products — at a slightly reduced capacity — using the existing Kallfass side boards sorting system.

Robust system for main products

The Kallfass delivery starts from the transverse take-off of the main product behind the sawing line. The sorting and stacking system is designed for timber lengths of 2.5 to 7.3 m and a maximum cross-section of 63 x 260 mm. “We have also tested 100 x 260 mm - that also worked without any problems thanks to the robust design”, says Production Manager Guillaume Cedan with a smile. First, the timber is separated.

A Tongloader with a capacity of up to 80 pieces per minute cycles the sawn timber onto an assessment chain conveyor. At this point, the machine manufacturer has incorporated an innovative feature, as Kallfass Managing Director Hans Haist points out during the tour: “Unlike before, when employees activated a button to ensure the timber’s quality or adjusting the wood, we have now provided a touch screen interface. Now, the operator can easily determine the quality”. The assessment chain conveyor facilitates the inspection of both timber faces. This was especially crucial for Dubot, since the sawmill prioritises sawn timber of the highest quality above all else.

Transfer using transport trolleys

The boxes are emptied onto a longitudinal conveyor and the wood is then transferred to a transport trolley. The trolley now travels at a right angle into the new parallel hall and the sawn timber is transferred to the step separator and unscrambler. Subsequently, layers of timber are created and the Kallfass multiple cross-cut saw is called into action. “The latter is equipped with five saw aggregates, four of which can be positioned automatically”, explains Jonathan Bleesz, who represents Kallfass in France with his company VBI. The mechanisation transfers the sawn timber layers to the stacker. Mr Haist estimates the output of the stacker to be up to ten layers per minute. The stacker is equipped with eight single-stack magazines into which the sticks are placed.

The finished sawn timber stacks are transported onto a generously dimensioned cross conveyor. The forklift operator either removes the timber stacks or feeds them to the existing strapping system, which Kallfass has integrated into the control system. “This area is now fully automated; employee involvement is unnecessary, and wood package data transfers automatically to the strapping system," Mr Haist explains.

Kallfass box sorting line, trieur à cases

Den Output verdreifachen EN Tripling the output

This is the target the French sawmill Blanc has committed itself to. Located in the Rhône-Alpes region in the south-east of the country, the family-run company is relying almost exclusively on German engineering technology for its ambitious project. Kallfass accounts for an elementary component of the extensive investment. The machine builders from Baden-Württemberg were commissioned to construct a flexible and versatile sorting system that is specially tailored to the needs of the French market and ensures Blanc's long-term competitiveness.

Strengthen market presence

In 2023, the sawmill was still cutting approx. 45,000 cubic metres per year. The aim is to break the 100,000 cubic metre mark as early as next year, more than doubling the output. The wood, mainly spruce, fir and Douglas fir, is sourced from the mountainous region of the Rhônes Alps and bordering with France, Switzerland and Italy. According to Blanc, the company has no supply problems to contend with and is also confident about the future in terms of sales: “We have already acquired a number of new customers who previously sourced their products from Scandinavian producers. We can deliver products of equal quality. We compensate for any price disadvantages with short delivery times and the possibility of local value adding,” explains Blanc.
The family-run company has always produced building products that are sold to value added wood manufacturing industries and, above all, timber construction companies. “We sell exclusively in France. In addition to our high quality, our customers particularly appreciate our versatility,” reports the company successor.
Board dimensions of 75 to 250 mm in width and 18 to 100 mm in thickness can be processed on the Kallfass system. “Almost everything that the French timber construction industry needs,” summarises Blanc. “The focus here is on building with wood. We are also noticing this in the increasing demand for our products. However, in order to further promote timber construction, producers must also be able to deliver.”

Successful general remodelling

To meet our objectives, construction of a new long-wood plant at the logyard started in 2022. Updates to the sawing line, edging system and scrap wood removal. As with the other machines, Blanc relies on an established German supplier, Kallfass, for the sorting system. “Only Kallfass could supply us with a system that combines flexibility and performance so efficiently. This offers the perfect balance of price and performance.,” says senior partner Frédéric Blanc, impressed by the Baden-Württemberg mechanical engineering company.

In November 2023, Kallfass finally began delivering the first components. Despite the comparatively large amount of conversion work required, the new sorting plant was able to go into operation in September of this year. “The existing hall had to be extended in both width and height for the new sorting system. With 79 boxes, our system at the Blanc sawmill is now the largest of its kind in France. However, it would not have been possible to manage the varied Blancs ranges otherwise,” says Jonathan Bleesz, Kallfass’ sales partner in France, giving an insight into the project.

Focus on versatility

The new system is 130 metres long and has two levels in order to be able to meet the customer's request for 79 vertical boxes. “The variety of dimensions is typical for French sawmills of this size. The market is looking for producers who can offer everything,” reports Bleesz, who has been working with Kallfass for over 15 years and is therefore very familiar with the special features of the French market.

Kallfass receives the sawn softwood from the sawmill via a double unscrambler, which transports the material to the higher assessment level in a first step. A curved chain conveyor moves the building products via the Tongloader to an assessment station for separation. Here, the trained eye of the operator determines the quality of the cut product. Up to six different qualities can be added to the wood at the touch of a button. “The system currently runs at approx. 80 cycles per minute - more would not be possible with a visual assessment. If a scanner is retrofitted, we can increase this to up to 120 cycles per minute - in terms of mechanical engineering, all precautions have been taken,” reports Bleesz.

After the quality assessment, the boards are transported one level further down via a level changer. The trimmer installed there has ten saw aggregates and can therefore react precisely to the quality assessment specifications. Once the filling volume of a box has been reached, it is emptied onto a chain conveyor and the timber is aligned and separated using a step separator. An operator monitors the layer creation before the sawn timber is sawn to the desired lengths on the multiple cross-cut saw and stacked into finished wood packages on the stacking system. The stacking system was equipped with automatically positionable double strip magazines in order to be able to flexibly place drying or transport sticks. With up to 14 layers per minute, the stacking system has also already been designed for Blanc's future increased production. “The aim was to build a sorting plant that would secure the company's long-term future. This also includes a significant increase in the current cutting performance,” confirms Bleesz.

It's not over by a long shot

Blanc is convinced that the right decision in choosing Kallfass as its supplier was made. In the future, however, the wood will not be loaded directly from the stacking system onto customers’ lorries, but the wood will be processed internally. “First, we need to get the sawmill operating at full capacity and make a few minor adjustments. In the future, however, we also want to refine our products ourselves and are therefore planning the possible construction of a glulam production facility. The first step has already been taken with the expansion of the sawmill’s capacity,” says Quentin Blanc confidently.

Weichen für die Zukunft erfolgreich gestellt EN Successfully setting the course for the future

The core values of Eurolegnami di Debortoli Fabrizio were established when the company was founded, more than 30 years ago. More than 2.5 million pallets leave the plant in Novaledo near Trento in northern Italy every year, destined for industrial customers in the surrounding regions and beyond. Fabrizio Debortoli, Managing Director, emphasizes the need for diversification beyond pallet production to ensure long-term competitiveness. Ultimately, the company's sawn timber supply is crucial to its overall success.

A fresh start

A few years ago, the next generation finally joined the family business. At the same time, the band sawmill's outdated systems were causing production delays, making significant investment in upgrades a necessity. Instead of a costly renovation, however, the decision was made to build a new building on a neighbouring industrial site. Eurolegnami was able to launch production at the new facility at the middle of the year. The company's 100,000 cubic meter annual capacity ensures they can fully supply their own pallet production while also being flexible to respond to market fluctuations in the sawn timber market.

Wood quality, a continuous challenge

Eurolegnami, as a pallet manufacturer, must buy all sawable roundwood assortments. Aside from the cut itself, fluctuating log quality poses a major problem for the sorting process and for handling the sawn timber as a whole. “We needed top-notch professionals in this area and Kallfass quickly stood out. Right from the start, they understood our situation, the requests and objectives of the new plant, and consequently came up with a suitable concept for us that more than met our expectations,” says Nadia Longhi, Administrative Manager at Eurolegnami, pleased to have made the right decision in selecting the perfect supplier for the new sawmill.

“Systems like those of Eurolegnami are part of our proven standard repertoire. This order is particularly satisfying because it establishes another significant reference point for us in the Trentino-Alto Adige region after several years.” says Kallfass Managing Director Hans Haist, speaking at a meeting in Novaledo.

Established concept

Kallfass takes responsibility for delivering both primary and side products from the sawing line onwards. After appropriate buffer solutions, the boards are separated at the first evaluation station. The operator can highlight the quality of wood parts by using a chalk line, and by pulling the wood forward any defective areas can be cut off subsequently using the zero saw. Next, six lasers scan the board, measuring its dimensions. Based on these measurements, each piece of wood is sorted into one of 25 designated boxes. Due to space limitations, Eurolegnami chose a vertical design of these boxes. “In the case of slanted boxes, we could have created a maximum of 20 boxes. However, using smaller pallet dimensions, there is no need to worry about damage, even if using a vertical design,” emphasises Haist during the guided tour.

Once a box is full, it is emptied and the boards are automatically separated using a step conveyor. An operator monitors the layer creation before each board is cut to the desired length on the multiple cross-cut saw from Kallfass. To maximize raw material efficiency in pallet production, Kallfass has integrated seven movable saw aggregates into the system. Haist points out that “In the pallet business, the yield of the raw material is crucial”. “Our focus is on precise, millimeter-accurate cutting to ensure the downstream pallet line receives exactly what it needs.” The boards vary in length, measuring between 600 mm and 5.2 m.

Once cut to size, the timber can either be stacked on the stacking system in an offset position or prepared for transport ready strapped, depending on the application. “Our stacking system has been reliable for years and, like the rest of the system, is remarkably user-friendly, making maintenance and operation straightforward. Depending on the workload, only two to three employees are needed on the line - the rest runs itself,” explains Haist.

Great customer confidence

The order situation at Kallfass remains good. “Some of our books are already well filled until 2026. The orders vary in scope, from minor modifications and updates to complete systems and large-scale projects. We are particularly pleased to have been able to once again demonstrate our pallet expertise in this project, enhancing Eurolegnami's preparedness for the future,” stated Haist with satisfaction.

Eurolegnami is pleased with the results of the project. “We were able to visit several sawmills in Germany at the beginning of the decision-making process. Today, we understand the reasons behind the significant customer loyalty to Kallfass,” explains Michele Debortoli, successor and junior manager.

Flexible Sortierlösung für KMU-Sägewerk EN Flexible sorting solution for SME sawmill

With a cutting capacity of around 25,000 cubic metres per year, the Wolf sawmill is a classic small and medium-sized enterprise (SME). The company's history dates back to 1870. Today, Christian Wolf runs the firm in cooperation with his mother, Gabriele Wolf, and represents the fifth generation of the family-run company. When using a gang saw and a small profiling system, and a downstream circular edger saw, the production of solid structural timber (KVH® for short), glued-laminated timber (GLT) lamellas, packaging squared timber, side products or raw goods from sawn timber (rough planer) is relatively easy. The classification and stacking of the diverse assortments were previously carried out using a simple length sorting system. In this case, employees subsequently stacked the sawn timber manually. “It was too labour-intensive and we find it very difficult to recruit staff. In addition, this sorting has significantly limited our performance,” explains Wolf. In order to become faster and more flexible, a new solution was needed.

Perfect handling

Wolf Jr. looked at several suppliers. Ultimately, he liked the concept of Kallfass, Baiersbronn-Klosterreichenbach, Germany, the best: “Kallfass has always built very reliable sorting systems and was able to complete the project in a very short time. I particularly liked the agility in the planning – all of our requests and ideas were implemented promptly and the new sorting system is specially adapted to the size of our sawmill,” explains Wolf. The renovation work was carried out last year, and the new Kallfass sorting and stacking system has been in operation at the Wolf sawmill since March. “The entire commissioning process went absolutely smoothly. The Kallfass technicians were excellent, as were the programmers," says Wolf, full of praise for the mechanisation specialist's handling. “We now have countless possibilities to deal with our qualities and dimensions.

Kallfass supplied the complete sorting and stacking system, from the transfer downstream of the trimming and circular resaw. The latter is designed for lengths of 1 to 5.1 m and a maximum cross-section of 140 x 180 mm. A conveyor belt transports the squared timber or the main product and boards to two separate buffer decks, which are positioned directly underneath the boxes. “The buffers are dimensioned in such a way that an entire sawmill production output of three to four hours of, for example squared timber, will find space,” explains Kallfass project manager Matthias Link.

After separation, the goods go to the assessment station. The employee can set a back cut of up to 50 cm at the zero line by dragging. If a cross cut is to be made on the opposite side of the wood, the wood is marked with a luminescent chalk. The cross-cut is done later, immediately before stacking. There is also a turning device in the area of the assessment station so that even heavy pieces of wood can be qualified on all four sides. Any unsuitable pieces of wood can be separated into planks and squared timber and ejected into two stanchions immediately after cutting.

“Only one assortment goes directly into the stacking system at a time,” reports Wolf. After the cross-cut station, the remainder is fed upwards to the box sorting system via a level changer. After several discussions, Wolf finally decided on 30 boxes. This means that the space has been used in the best possible way. The boxes are emptied downwards onto a chain conveyor above the buffer decks. The wood then takes the same route as the unsorted goods towards the stacking system.

In order to be able to produce short lengths with millimetre precision, Kallfass installed the proven multiple cross-cut saw. The latter is equipped with four saw aggregates, three of which can be positioned automatically. In order to be able to respond to even more flexible to customer requirements, Wolf is already considering retrofitting a fifth saw aggregate. After layer creation, stacking forks transfer the lumber to the stacking system, which is equipped with four double magazines for drying and dispatch sticks. Finally, a conveyor unit supplies the sawn wood packages. While still in the planning process, Kallfass has already anticipated the possibility of conveniently retrofitting a strapping system.

In order to be able to re-sort dry packages, there is an external infeed. Here, the wood is separated layer by layer using a chain conveyor, which then transports the timber towards the assessment station. The sticks are carried via a conveyor belt into stanchions and removed.

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.

Enhanced performance and superior quality

Kallfass has now delivered the fourth system to Dubot. Shown in the picture: Guillaume Cedan and Florian Baudron from Dubot with Kallfass Managing Director Hans Haist and representative Jonathan Bleesz (from left)

Robust system for main products

Installed by Kallfass for the first time: Now, the employee can inspect both faces of the timber using the assessment chain conveyor. He then enters the quality on the touch screen.

The new sorting plant now has 22 boxes. This means there is no longer a bottleneck.

Transfer using transport trolleys

After emptying, the timber is placed on a moving device; subsequently, the timber is fed to the stacking system

Proven many times over and an indispensable part of any Kallfass system: the multiple cross-cut saw

The stacking system is housed in a new hall, parallel to the box sorting system. The picture shows the generously dimensioned package chain conveyor.

Kallfass also supplied a Microtec wane scanner and a trimmer.

Strengthen market presence

Happy about the collaboration: Jonathan Bleesz, Kallfass’ French representative, together with Quentin, Frédéric and Brigitte Blanc (from left) in front of the new sorting line

Successful general remodelling

Hall extension: The existing hall had to be extended for the new Kallfass system

Focus on versatility

Thick, thin, wide and narrow: At the Blanc sawmill, the sawn timber assortments are colourfully mixed on the Kallfass sorting system. A task that the specialists knew how to master

Decides on the quality: An operator assesses the wood quality with a trained eye. A scanner could also be installed here in the future

It's not over by a long shot

Thick, thin, wide and narrow: At the Blanc sawmill, the sawn timber assortments are colourfully mixed on the Kallfass sorting system. A task that the specialists knew how to master

Decides on the quality: An operator assesses the wood quality with a trained eye. A scanner could also be installed here in the future

Established concept: View of the multiple cross-cut saw and the stacking system at the end of the new hall

A fresh start

Company succession secured: Kallfass Managing Director Hans Haist (left) together with Michele and Vania Debortoli

Wood quality, a continuous challenge

Focus on self-sufficiency: Eurolegnami's primary objective in establishing the new sawmill is to secure a long-term supply of lumber for its pallet manufacturing operations

Established concept

Everything under control: The worker inspects the wood and by pulling the wood forward any defective areas can be cut off subsequently and with a piece of chalk he indicates the board's quality.

Efficient and economical: Kallfass puts the output of the sorting system at a maximum of 120 cycles/min

Great customer confidence

Minimum cut length: The shortest cutting length of the Kallfass multiple cross-cut saw at Eurolegnami is just 600 mm

Efficient and economical: Kallfass puts the output of the sorting system at a maximum of 120 cycles/min

Stacked and strapped, the sawn timber packages are ready for internal processing on the Eurolegnamis pallet production lines

Existing space used as best as possible

Perfect handling

Trusted in Kallfass’s expertise: Christian Wolf (left) with Kallfass project manager Matthias Link

”Kallfass delivered a system that was perfectly tailored to our needs.”

Separation of the boards and squared timbers towards the assessment station

The employee examines the cut material and can determine a cross-cut by pulling it

Kallfass also carried out an external infeed for dry wood packages

The proven multiple cross-cut saw from Kallfass cuts the wood with millimetre precision

Investment has paid off

Feeding to the upper floor to the 30 boxes

The finished wood packages are placed on a roller conveyor – there is also space for a strapping machine

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