Kallfass Sonderlösungen für Deckenelement-Werk

Leimholzwerk spielt alle Stücke EN Glued timber plant has it all

Multi-storey production for multi-storey timber construction

Step-by-step, Best Wood Schneider has filled its new ceiling element plant with more and more processing steps over the last few years. On three floors it now has a BSH line (glued-laminated timber) and a BSP line (cross-laminated timber) line, from which trimmed and glazed rib elements can be produced downstream. The bulk of the highly complex production was planned and realised in close cooperation with Kallfass.

With the “best wood CLT Box Ceiling”, Best Wood Schneider from Eberhardzell in Germany, has successfully combined the positive properties of BSP and BSH. The combination of glued-laminated timber and ribbed beams results in a structurally effective and at the same time space-creating timber element which is comparatively low in weight. Finish-trimmed and glazed, the result is a high degree of prefabrication with quick installation times on site.
Explained in a few short sentences here, these wooden box elements are the result of many years of development work, which also posed major challenges in terms of machine and plant engineering too. “We produce exclusively to order and offer our customers a wide range of products and finishing steps,” explains Schneider Project Manager Andreas Schilling and adds: “In addition, there is the complex arrangement of the production lines over a number of levels.” Schneider realised the plant over three storeys with numerous interim levels – the timbers are transported back and forth for the individual processing steps between the levels at 0 m, 6.5 m and 12.5 m by two lifts, before the automatic transfer of the finished elements to a high-bay warehouse. “This arrangement saves building land and above all means shorter distances within production,” says Managing Director Ferdinand Schneider, explaining the advantages of this arrangement.

Vollautomatisches Regalbediengerät

A fully automated storage and retrieval system links the individual processing steps with each other.

New production process

As one of the main suppliers, the tradition-steeped Swabian company Kallfass was commissioned for much of the planning work and also supplied large system components for all three levels of the production system. The Kallfass installation begins on the top floor where the single-layer boards are taken in. Elements which are later used for the transverse layers of the BSP, which is up to 1.25 m in width, are cut to length by a chop saw. The transverse layers are then lowered by a lift table and rotated through 90°. The downstream lay-up station uses longitudinal and transverse layers as well as a glue application station to produce the 16 m long layer package, which is transferred to the CLT press of another manufacturer.

“For the production of the ribbed ceilings we developed and realised a process with Schneider which had not previously existed in this form before.”

Hans Haist, Managing Director at Kallfass

After the press the boards seem to be spoilt for choice – but they always end up exactly where they are supposed to be, in dependency on each order. “A roller conveyor on rails installed by us picks up the boards and, in accordance with the instructions from the master computer, brings them to the glazing line, planer, trimming centre or to the storage and retrieval system realised by us,” says Kallfass Managing Director Hans Haist, explaining the options. The latter is fully automated, places the components in interim storage and links the individual processing steps with each other. For example, the storage and retrieval system also charges the rib element production system, whereby Haist does not wish to provide further details about this part of the installation, with the following reasoning: “For the production of the ribbed ceilings we developed and realised a process with Schneider which had not previously existed in this form before.” The rib elements can be finish-trimmed and/or sanded and glazed after production – just like the BSP elements.

Ready-made laminated beam ceilings

On the middle floor, 6.5 m above ground level, Schneider produces the laminated beam elements. This is dealt with by Kallfass and it transfers them on – depending on the order – for further processing or stretch foil wrapping, after which the elements are moved on to the high-bay warehouse immediately downstream.
In the same way as for the box elements, Schneider also offers its customers glazing for the laminated beam ceilings. If this is required, an inclined lift, also from Kallfass, brings the parts to the ground floor. Here, Schneider employees rectify any surface damage before the elements run through a two-stage sanding and glazing process. On this level Kallfass is responsible for the complete mechanised solution between the machines.

The glazed elements are transferred back to the middle floor again by the same inclined lift, where they are also packetised, packaged and placed in storage. From the high-bay warehouse the packages are transferred via a conveyor system to a central truck loading station, which was realised by Kallfass some years ago.

Erfolgreiches Projekt von Kallfass und best wood Schneider

Following the successful project at the headquarters, talks get straight under way about the next major project together in Meßkirch.

Maximum flexibility

In the event of a fault – for example, the failure of one of the two glazing lines – Schneider can reschedule the elements along the running line at any time. “This maximum flexibility in terms of production, namely that every element can run through all possible production stages and can be fed in and out at any point was demanded by Schneider and was one of the biggest challenges of this project,” stressed Haist. That this worked out successfully and all other promises made by Kallfass were fulfilled to the satisfaction of Schneider is perhaps best confirmed by the follow-up order: In Meßkirch, Best Wood Schneider is currently realising a production line which is envisaged to set new standards, especially in terms of logistics – from log deliveries to the finished BSP, the aim is to completely dispense with stackers. The systems from Kallfass will once again play a central role here too.

Kallfass Wender zur Positionsausrichtung

A turning device moves the element into the correct position. Since many of the timbers are produced in exposed quality, this is particularly gentle on the material.

Zwei Kallfass-Aufzüge verbinden drei Produktionsebenen

Two lifts from Kallfass connect the three levels for the timbers.

BSP-Platten lasiert und abgebunden

Depending on the order, the BSP boards are glazed, trimmed and/or processed further into rib elements.

Kallfass Sonderlösungen für Deckenelement-Werk

Kallfass is one of the main suppliers at the Schneider ceiling element plant and supplied numerous special solutions.

Erfolgreiches Projekt von Kallfass und best wood Schneider

Following the successful project at the headquarters, talks get straight under way about the next major project together in Meßkirch: Max (left) and Ferdinand (third from left) Schneider and Andreas Schilling (right) from Best Wood Schneider together with the Kallfass managing directors.

Images and text: Günther Jauk, Holzkurier
Holzkurier BSP-Special 2021

Etikettierung und Bündelung

Alle 50 Sekunden:
ein 4m-Paket EN
A 4 m package every 50 seconds

From S10 to KVH structural timber – planing, marking, labelling, bundling, foil wrapping, stacking of everything at up to 200 m/min

The extraordinary business success of Cordes Holz in Bremerhaven has compelled it to upgrade the planing unit after only two years. The plant was developed, expanded and modernised, and the result is a completely new Kallfass planing mill.

Kallfass had started the planing unit at Cordes Holz at the turn of the year 2018/2019. At that time, the line was, in essence, explicitly designed for DIY store products all over Europe. “The plant was extremely robust and very quick. In fact, it went so well that, despite our complete satisfaction, we were obliged to order an upgrade of the machine from Kallfass two years later”, explains Andreas Cordes, the owner. His primary wish was to enhance the level of flexibility with regard to dimensioning. And, while they were at it, they could also expand the marking options and, once again, increase the performance of the planing machine.

“The success of the machine forced us to upgrade after only two years”

Andreas Cordes

Takes on everything up to 290 mm and 6 m in length

What emerged was a universal plant that can do everything “from an S10 batten to raw solid structural timber, and from rhombic sections to square planing”, as Cordes describes it. That is considerably more products than could previously be manufactured. The maximum cross section is 290 mm by 165 mm and length of 6 m. Output was increased, despite comprehensive marking, labelling, foil wrapping, bundling and stacking options. The mechanisation is so powerful that the Rex Bigmaster could be enhanced from 100 to 200 m/min. The planing unit was designed for smaller solid structural timber cross sections, but it can now reach twice the speed and handle a much broader dimensional spectrum.

22 fitters for “open-heart surgery”

Kallfass realised the conversion during continuing operation. Up to 22 fitters were required to ensure that the general reconstruction could be achieved within ten weeks with only a single brief shutdown. “Actually, everything was changed, with the plant being expanded in three directions, and a lot of scanners, sensors and marking units were added”, explains Kallfass Project Manager Enrico Goldhahn. “It was open-heart surgery, and we performed it by working in two shifts, including over the weekend. We’re proud that, in spite of all the changes, hardly any stoppage occurred”.

Lagenweise Entstapelung, Leistenscanner mit Leistenabstreifung

There is a lot going on at the planing facility entrance: layer by layer separation, stick discharge, stick scanner, dimension check and feeding into the Bigmaster

Joint concept

“The plant, as it now exists, was a joint development undertaken by REA Jet, Cordes and us”, says Goldhahn. Among other things, he recommended that a buffer conveyor be installed upstream of the destacking device. The plant picks up an uninterrupted stream of packages for vacuum destacking. “We suggested here that a vacuum destacker with a hoisting unit, stick stripper and ATB stick scanner be selected, and that’s exactly how it was constructed”, relates Goldhahn.
At Cordes, timbers that are too short or unsuitable can be separated upstream of the planing unit. “It’s not unusual for a short piece to be delivered with a package, but I can do without that in the planing mill”, explains Cordes, which is also why a warping meter from ATB in Roggenburg, Germany and a turning device were installed here.

Powerful, despite many processing options and cutting

The first REA Jet labelling run then followed, printing all the required information on the DIY products. The downstream multiple cross-cut saw is from Kallfass. “We can now trim with millimetre accuracy. From 800 mm short timbers to 6 m excess lengths – that means we’re extremely flexible”, says Cordes with delight during the tour of the new planing mill.
He can also call up the plant performance data live on his mobile phone. During the on-site visit of the Holzkurier, a 4m DIY package was completed every 50 seconds.

Folierung, Umreifung, Paketzettel

Foil wrapping, strapping, packet note – everything compact

Six strapping units for small and large pieces

“We delivered the first plant to Cordes with six strapping machines for bundling small and large pieces”, continues Goldhahn. Finally, the packages can also be wrapped in foil. Kallfass also provided an offsetting station for quart packages. The stacking system can handle both small and large packages up to a package height of 2.4 m. “The automatic squared timber stacking is accelerated further, making everything perfect”, says Goldhahn, explaining the success.

Only two operators for the plant

Only two employees work in the plant on each shift. The team monitors the process and ensures that material such as labelling rolls is filled. Just how well the two work together became apparent during the visit. One of them focuses on feeding timber pieces up to the rear of the planing machine. A fault must be remedied here in the case of broken raw timber, or labelling rolls inserted. The second man stands beside the package assembly system. Bearers (squared timbers) or sticks are refilled there.

Praise from the biggest name in Germany

If Andreas Cordes accepts the plant by saying “We’re very satisfied”, his words carry weight. This is the judgement of a man whose corporate group includes German planing specialists such as Osmo Holz in Warendorf, Holz-Henkel in Göttingen and Krages Holzindustrie in Hamburg. In addition, Rettenmeier, a subsidiary, also creates planed workpieces at several locations. This means that the Cordes Group probably has the greatest planing capacity in Germany.

Cordes still has major plans for Bremerhaven. Solid structural timber will be increased to 200,000 m³ per annum, along with an additional 50,000 m³ a year of glued laminated timber. Kallfass is a significant partner for deliveries of these systems. A test run should commence this year.

Three stacks wait in front of the facility, with timber fed in automatically

Enrico Goldhahn und Andreas Cordes

Enrico Goldhahn and Andreas Cordes (from left): The Kallfass project manager and the Cordes Group owner

Hobelbeschickung mit Hochgeschwindigkeit

Enhanced planing unit: the Rex Bigmaster now runs at up to 200 m/min

Integrierte Etikettierung

Marking at full speed: units supplied by REA Jet

Millimetergenaue Kappung mit Mehrfachablängsäge

Trimming with millimetre accuracy, whether 80 cm short timbers or 290 mm solid structural timbers

Automatische Paket-Kantholzlegung

Automatic package squared timber stacking

Text and images: Gerd Ebner, Holzkurier
Holzkurier 26/2021

Die Leistensortierung mit Roboter

Automatisch im Vorteil EN Automatic Benefits

Murray Timber Group has installed a Kallfass stacking line to increase automation and boost capacity. Sally Spencer reports

Installing a new stacking line at a busy sawmill in the middle of a pandemic might be a challenge too far for some, but for Murray Timber Group (MTG) and Kallfass it was pretty much business as usual.

The Irish sawmiller, a major processor and exporter of construction, fencing, pallet and packaging timber, had been keen to increase capacity and reduce manual handling at the Ballygar mill and back in May 2019 had placed an order with Kallfass for a stacking line for squared timber for kiln drying and dispatch packages.

The working relationship between MTG and Kallfass stretches back to the installation of a cross-cut and stacking line in 1995. The quality and technical ability of that line had impressed, said Matthias Link, Kallfass sales manager and the companies had maintained contact since then. So when the time came for an upgrade, Kallfass was the name in the frame and after visiting the company and seeing some examples of similar installations in Germany and Austria, the deal – worth around €2m – was struck.

At that point, of course, no one had even heard of Covid-19, let alone knew the impact it would have, but MTG was determined to press ahead and installation started in June last year. Prior to the work starting, the existing building was extended and a new concrete floor was poured, but the mill continued to operate as normal and there were no shutdowns during the installation.

“MTG wanted to have the machinery installed and they did everything to realise that. The pandemic didn’t hinder the early stages of the installation."

Matthias Link, Kallfass sales manager

The Kallfass operatives on site included one mechanic (sometimes two), two electricians and, at the end of the year, one programmer – but Matthias stresses that they “had very good support” from the MTG team. “It was very good to work together with them,” he said, adding that the company was always in step with Kallfass’s schedule and always ready for the next stage of the installation.

However, at the end of the year it became more and more difficult for Kallfass to travel to Ireland and a lot of improvements had to be made via remote service. “MTG had installed cameras at different points of the installation so it was possible for us to see what was happening, recommend adjustments and then to look back to see if they had helped,” said Matthias. It also helped that the MTG team is very skilled technically and was able to describe issues and relay information very precisely.”

The cross-cutting and stacking line can be charged in two different ways. One entry point is from the existing sorter, where the material is taken in batches via an angle transfer and transported to the new line. The complete content of a sorting box (the maximum wood length is 5.3m) is emptied in a batch onto a cross conveyor and transported to the new part of the line. The other entry point takes material from the kiln or from other packages and is de-stacked, cut to length, stacked again and strapped.

If the material is fed via the tilt destacker, the packages (maximum size 1240mm wide x 1500mm high x 5300mm long) are destacked and the sticks removed from the wooden boards and then ejected into a deposit box via a belt conveyor. The boards are transported in layers via an angular chain conveyor to a step feeder. An unscrambler separates the material which is then aligned on a common zero line. Now the operator visually assesses the timber and if end trimming is necessary, pulls the board for subsequent trimming of flaws and wanes.

The boards are now fed layer by layer to the multiple cross-cutting saw, which is equipped with five variably positioned, pneumatically controlled chop saws. Two of the saw units can be pivoted by 30°. The indirect drive allows boards to be sawn to a minimum length of 750 +/- 1mm. A maximum of 10 layers per minute are stacked into packs. The packs are either taken from the front with the forklift, or transported to the strapping machine.

“If the material is going on into the kilns it doesn’t need to be strapped, but packs ready for dispatch will be strapped,” explained Matthias.

“The big decision maker was the robot sticking machine, which was the solution we had been searching a long time to find.”

Spokesperson Murray Timber Group

Die Leistensortierung mit Roboter

The robot sticking machine in action

One of the main attractions of the new stacking line for MTG was Kallfass’s patented automatic stick feeding system with a performance of 80 sticks a minute. This is the first installation of its type in the UK and Ireland. The stick bundles are placed with the forklift between the guide walls of the buffer conveyor and are then transported to the unscrambler. The separated sticks pass a scanner and damaged sticks are ejected. The sticks then move to the stick bundling part of the process where they are grouped into packs of 12. These are fed to buffer conveyors and, following alignment, Kallfass’s patented robot grabs the bundles and feeds them into eight double magazines equipped with two shafts each. The double magazines are needed to handle two different stick sizes.

The automatic stick feeder is used for the sticks measuring 44x22mm that are used in the kilns. The smaller sticks (44x10mm and 35x10mm) used for timber packs ready to be dispatched are placed manually in a designated buffer conveyor from where the robot picks up the sticks and feeds the second shaft of the stick magazines.

The strapping is equipped with two bearer magazines. The bearers are strapped together with the pack. A strapping cycle, including pack positioning, takes no longer than 18 seconds. The packs are taken off the subsequent angular transfer with a forklift.

Matthias estimates that the line is running at around 90% capacity and says that as soon as Covid restrictions ease and international travel is allowed, Kallfass will return to the Ballygar mill to carry out some final fine-tuning.

MTG says it is very familiar with the Kallfass equipment and is very comfortable with it from a quality, design and performance point of view.

“The big decision maker was the robot sticking machine, which was the solution we had been searching a long time to find,” said a spokesperson. "It was perfect for what we wanted, fully automated, high performance and completely flexible as to where the sticks can be placed,” he continued. “We are very proud to have one.”

Stapelanlage mit Leistenmagazinen, Befüllung durch Roboter

The stick sorter line - the robot can be seen in the background

Installation of the new line began in June 2020

TTJ Timber Trade Journal May/June 2021, pictures Murray Timber Group and text Sally Spencer
TTJOnline May/June

Manueller Beurteilungskettenförderer

Alles unter Kontrolle EN EVERYTHING UNDER CONTROL

The decisive economic factors in timber processing are product quality and production utilisation. Quality assessment systems integrated in the production process increase the automation level and, simultaneously, optimise utilisation.

Optimised cutting in networked production

KALLFASS has developed an interface concept that networks different software systems in a production line, thus enabling direct communication between individual processes. For example, the wane scanner installed in the sorting system determines board dimensions such as length, width, thickness and possibly quality, identifies flaws such as knotholes or wane and transmits these measurement results as cutting information directly to the KALLFASS trimmer saw. Trimmer saws normally only work with preconfigured grid lengths, but adding equipment to the system such as a servo-controlled, flexible zero stop upstream of the trimmer can cut out flaws with great precision while minimising the loss of wood.

As an alternative to scanning, the KALLFASS assessment chain conveyor can be used for a manual quality assessment of timber. Each board is individually accommodated and rotated through 180° before being deposited again on the conveyor. The operator can observe the timber from all sides and assign a characteristic.

Manueller Beurteilungskettenförderer

Alternatives to scanning: Manual quality assessment of timber with the KALLFASS assessment chain conveyor.

Holzkurier 13/2021

Schrägboxensortierung

Schmuckstück:
Neues Schwachholzsägewerk EN
An Absolute Jewel:
New Thinnings Sawmill

Smart, clean and safe

Kickoff in Wunsiedel was December 2019, with the first trunk being fed through the new line exactly one year later. Construction of the GELO Timber sawmill continued during the most difficult times imaginable. Despite all the adversities the Corona pandemic presented, it proved possible to adhere to an already tight schedule.

The main product, predominantly DBH lamellas, is intended for the supply of laminated wood plants. Side boards which cannot be processed are supplied to packaging customers. “The sawmill will reduce purchasing considerably for both companies in future. 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.

Gelo Boxensortierwerk

Excellent cooperation: Wolf-Christian Küspert (l.) with Kallfass Project Manager Matthias Link.

Clean sorting and packetising

Main and side boards from the HewSaw line are conveyed in two decks to the sorting and stacking system from Kallfass in Baiersbronn-Klosterreichenbach/DE. The mechanisation specialist also installed an automated stick feeder. The main and side boards are fed through a separator 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 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.

“This is an absolute jewel, and we’re proud to have commissioned the plant on schedule, especially in such a challenging time”.

Wolf-Christian Küspert, Managing Director GELO Timber

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 fresh 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 chop saws. Placement forks then transfer the completed layers to the packet assembly system. Stacking output is up to twelve layers per minute.

The Kallfass packet assembly 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. Fresh 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, a fixture collects the sticks, bundling ten sticks together in each case. Dispatch sticks are provided using a manually charged pouch 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.

Vereinzeler

The main and side board assortments are fed to the Kallfass sorting and stacking system via two buffer decks and a curved conveyor.

The worker pulls the boards forwards for the end section, with rollers facilitating the work.

Eintaktung mit Tongloader

The TongLoader ensures a rapid cycle feed towards the scanner and inclined boxes.

Mehrfachablängsäge mit vier variablen Sägen

The multiple cross-cut saw from Kallfass trims the layers with a zero line and four variable saws.

Leisten-Doppelmagazine

GELO Timber employs a stick robot from Kallfass to facilitate filling of the double magazine.

Gestapeltes Schnittholzpaket

One of the first completed timber packages from GELO Timber in Wunsiedel – cleanly cut, stacked and dried and destined for laminated wood production.

Images and text: Martina Nöstler, Holzkurier 11/2021
OLYMPUS DIGITAL CAMERA

Kontinuierlicher Zufluss
mit Leistenroboter EN
Continuous inflow with stick robot

Handling of stacking sticks often appears to be something of a “side issue”. However, the Kallfass installation at the Sägewerk Egger sawmill in Brilon demonstrates the enormous workload reduction automatic feeding brings in packet assembly.

Several thousand stacking sticks need to be handled daily at the Sägewerk Egger sawmill in Brilon. “Previously, the continuous filling of stacking plant magazines during main and side board sorting was an enormously laborious task”, relates Jens-Michael von Werder who is responsible for production technology at the sawmill. Up to nine workers were involved in each shift, which meant a considerable number of personnel were working during three-shift operation. For this reason, it was decided to invest in an automated stick handling system with robot charging of magazines at Egger.

Flexible solution

“We found the standard variants available too rigid. We wanted a flexible solution which we could use to handle both drying chamber and stabilisation battens and squared timbers”, continues von Werder. Kallfass, Baiersbronn/DE, offered Egger the perfect solution. “We’d already gain a positive impression of Kallfass during a project in the planing mill. Aside from this, Kallfass has always proved to be a good partner when it came to tackling challenging tasks”, says von Werder. The mechanisation specialist presented those responsible at Egger with a flexible solution that appeared to offer them cutting-edge technology. “We had already installed other automated stick systems in the past, but the project at Egger in Brilon was the most comprehensive to date”, explains Kallfass Managing Director Hans Haist.

Geschäftsleitung Kallfass mit Projektleiter von Sägewerk Egger

In front of the sticks being fed in: Ernst Kallfass, Jens-Michael von Werder and Hans Haist (l. to r.)

Two lines, three robots

The “open-heart surgery”, as von Werder describes it, was performed from April to September, with Kallfass realising the entire automated stick line installation while plant operation continued. The actual installation took two months. “The project went very well and, most importantly, free of accidents. We had practically no downtimes”, confirms von Werder. Egger in Brilon cuts around 1 million m² per annum. The timber is sorted in main and side board plants which are installed in parallel. The new Kallfass line charges both plants with drying chamber and stabilisation battens and squared timbers. Stacking sticks from the dry sorting station are fed together with the squared timbers in uprights to the new Kallfass line. The uprights are discharged onto a buffer conveyor. The system automatically separates the squared timbers from the sticks. The squared timbers are then fed to a stacking system via a separate chain buffer line. The Kallfass control system assigns the squared timbers to both stacking plants based on package data. The sticks take another route, with the Kallfass mechanism separating these and feeding them through a scanner. This determines the dimensions and curvature. Unsuitable sticks are discharged through a flap. The system handles eleven sticks together in each case on an inclined conveyor.

“We anticipate the new stick handling system paying off within a very short space of time”.

Jens-Michael von Werder, responsible for production technology

Andrea, Hubertus and Paul

Andrea, the first robot on the line, grabs these eleven stacking sticks and cycles them into the buffer conveyor. “This is designed for around 3000 sticks”, explains Haist. Hubertus and Paul, the two other robots with swivel arms, pick up the stacking sticks if necessary and deposit them in the new Kallfass packet assembly magazines. “The system is designed for an output of 100 sticks per minute”, estimates Haist. “We hold the property rights to this robot charger”, he adds. There is only one stick length for all package widths in the case of stabilisation battens. These are adapted to the package through positioning and shifting of stick placement. “This solution means we are considerably more flexible than with different lengths, but the cost of materials is higher”, says von Werder. Kallfass also upgraded the stacker and delivered the entire control system over the course of this investment. This means that it is now possible to control the placement of more sticks in the lower five to six layers to prevent timber breakage. From Egger’s point of view, operation of the new stick handling system has been both smooth and absolutely satisfactory. “The goal in the area of stick handling is to now manage with four employees per shift. This means the investment will pay off within a very short space of time”, concludes von Werder.

Zuführung Stapelleisten in Richtung Scanner

Feeding the stacking sticks towards the scanner that determines the dimensions and curvature.

Leisteneintaktung Hauptware

… while "Hubertus" is responsible for the main board plant.

Zusammenfassung Leisten

The Kallfass system picks up eleven sticks in each case which are cycled onto the buffer conveyor by Andrea.

Leistenmagazine

Kallfass also upgraded the stacker during the course of the new system installation.

Befüllung Leistenmagazine mit Roboter

"Paul" grabs these sticks and fills the side board plant magazines with them …

Stapelpaket mit Stapelleisten

More stacking sticks can be placed in the lower five to six layers to prevent timber breakage.

Photos and text: Martina Nöstler, Holzkurier 51-52/2020

Kallfass-Hegener_Zufuehrung-von-Saege

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.

Hegener
Kallfass-Hegener_Sortimente-gemischt

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.

Kallfass-Hegener_Zufuehrung-von-Saege

Kallfass is responsible for a major part of the mechanisation at Hegener-Hachmann in the sawmill and the complete sorting and stacking plant.

Kallfass-Hegener_Sortimente-gemischt

A special feature: Hegener-Hachmann can sort different dimensions in a single box.

Hegener_Beurteilung

A worker takes a final look at the boards before they enter the stacking plant.

Hegener_Crosscutting

Kallfass also installed the reliable CNC multiple cross-cut saw.

Hegner_Paket-Drehung

A speciality, thanks to the space conditions: The packages arrive on the right from the stacking plant on the lower level, are pivoted through 90°on rails and then enter the strapping station.

Hegener

Excellent cooperation: Markus von Weichs, Kallfass Managing Directors Hans Haist and Ernst Kallfass and Hubertus Hegener-Hachmann (l. to r.).

Hegener_Gutshofdiele

Gutshofdiele: The Hegener-Hachmann sawmill markets its high-quality solid hard and softwood flooring under the Gutshofdiele name.

Elektromeister / Industriemeister Elektrotechnik EN MASTER ELECTRICIAN / INDUSTRY MASTER (ELECTRICAL ENGINEERING)

Your duties

  • Assignment of tasks to employees in the e-department
  • Supervision of execution of electrical work
  • Supervision of completion of installations and control cabinets according to the specifications of the project schedule
  • Preparation of electrical documentation for our projects

What we offer:

  • We offer training and induction in an interesting and secure workplace
  • A motivated team awaits you
  • Performance-based remuneration, employee participation scheme and other social benefits

Your contact address for an application to

Location Klosterreichenbach
Kallfass GmbH
Maschinen plus Automation
Röter Straße 44
D-72270 Baiersbronn

Contact: Volker Kallfass
Phone: +49 (0) 7442-84460
E-Mail: karriere@kallfass-online.com

Elektromonteur Außendienst EN ELECTRICIAL FIELD SERVICE

Your duties

  • Electrical installation in industrial plants in the field of automation
  • Control cabinet construction
  • Reading and understanding circuit diagrams

Your profile:

  • Knowledge in the field of automation technology
  • Professional experience as an electrician
  • Autonomous and independent work
  • Willingness to travel (70-80 %)
  • Good English language skills

What we offer:

  • We offer training and induction in an interesting and secure workplace
  • A motivated team awaits you
  • Performance-based remuneration, employee participation scheme and other social benefits

Your contact address for an application to

Location Klosterreichenbach
Kallfass GmbH
Maschinen plus Automation
Röter Straße 44
D-72270 Baiersbronn

Contact: Volker Kallfass
Phone: +49 (0) 7442-84460
E-Mail: karriere@kallfass-online.com

Industriemechaniker / Maschinenbaumechaniker EN INDUSTRIAL MECHANIC / MECHANICAL ENGINEERING TECHNICIAN

Your duties

  • Production and installation of assemblies in the company
  • Good knowledge of reading technical drawings and assembly plans
  • Welding using the MAG and/or MMA process

Your profile:

  • Completed apprenticeship as a precision mechanic or industrial mechanic or comparable training
  • Good knowledge of reading technical drawings and assembly plans
  • Ideally, several years of professional experience in a comparable position
  • Knowledge of hydraulics and pneumatics
  • Flexibility, ability to work in a team and a willingness to travel
  • An independent and reliable method of working
  • A friendly demeanour and commitment
  • Willingsness to travel

What we offer:

  • We offer training and induction in an interesting and secure workplace
  • A motivated team awaits you
  • Performance-based remuneration, employee participation scheme and other social benefits

Your contact address for an application to

Location Klosterreichenbach
Kallfass GmbH
Maschinen plus Automation
Röter Straße 44
D-72270 Baiersbronn

Contact: Volker Kallfass
Phone: +49(0)7442-84460
E-Mail: karriere@kallfass-online.com