Kallfass Gebäude Klosterreichenbach und Wernigerode

Kallfass investiert in die Zukunft EN Kallfass invests in the future

Short production routes in Klosterreichenbach and more office space in Wernigerode are the goals of these construction measures.

When the demand for orders increases so dramatically that production reaches its limits in terms of capacity and the electrical department urgently needs more space to accommodate the increase in personnel, the only viable solution is to build and expand the existing production and office premises. Last year, the machine manufacturer Kallfass decided to go all out and invest and build in both locations.

The production area in Klosterreichenbach will be increased by approximately 600 m². An L-shaped extension to the existing production premises facilitates the improved integration of individual production stages in a direct time sequence. Routes are shortened and the entire production facility made more efficient as a result. Building commenced on 10 May. Planned completion is the end of this / start of next year.

Anbau Kallfass Klosterreichenbach

Excavators begin digging out the foundations in Klosterreichenbach.

New offices in Wernigerode

New offices are urgently needed at the plant in Wernigerode, Saxony-Anhalt. The production area was continually increased in recent years, but the offices have not been changed since 1992, even though the workforce has tripled in this period. Enlarging of the administrative premises by around 160m² to a total of 480m² is planned. The first implementation stage will see the creation of new parking spaces, as the extension will be erected on the original car park. Work on this stage has already commenced. Enrico Goldhahn, Plant Manager in Wernigerode, looks forward to completion of this extension by the beginning of 2023.

Both extensions represent an important step in accommodating the growing demand in future.

Anbaufläche Kallfass Klosterreichenbach

Rear view of the Kallfass production facility in Klosterreichenbach with the extension space.

Neue Parkplätze Kallfass Wernigerode

New parking spaces are being created in front of the building in Wernigerode.

Schnittholz in Pufferspeicher, cut wood in buffer levels

Optimales Kurzholzhandling EN Optimum short log handling

Tailored solution for an exceptional sawmill

With log lengths of 1.1 m and over, the Lithuanian Juodeliai Group recently commissioned a high-performance sawmill for producing raw material for pallets. Machine suppliers were also faced with major challenges, given the short logs involved and a planned output of 250,000 m³ of sawn timber per annum. Extensive experience and the level of commitment on the part of suppliers such as Kallfass ensured the success of the project.

The latest and, simultaneously, largest sawmill in the Juodeliai Group is currently operating in Marijampole/LT. The largest sawmill group in the country encompasses four locations and is responsible for cutting over 1.3 million solid cubic metres of logs per annum. Juodeliai aims to produce around 650,000 m³ of pallet timber in 2022, generating over € 200 million in turnover as a result. With customers in over 40 countries, the company is highly export oriented, although, according to CEO Andrius Zimnickas, no business relations are cultivated with Russia or Belarus, despite their geographic proximity. The company mainly obtains its spruce and pine logs and, also, hardwoods from Lithuania, a fact that also makes Juodeliai the largest consumer of timber in the country.

The company commissioned a fourth sawmill in 2020 in Marijampole, about a two-hour drive west of the capital Vilnius. Designed for an annual capacity of 250,000 m³, Juodeliai also produces pallet timber there for the global market. When it came to machine suppliers, the company opted for proven plant solutions from companies such as Linck, Holtec, Microtec and Kallfass. The latter is responsible for the mechanisation, sorting and stacking of main products and side boards.

„A practical, solution-oriented approach is the main reason we are cooperating again with Kallfass.“

Andrius Zimnickas, Juodeliai Group CEO

A challenging project

Kallfass takes charge of the main product upstream of the two multi-blade saws. A vertical system transports the separated logs as a whole to a peel-off system. Aided by gravity, these form a veritable carpet of boards. After passing a visual inspection station, layers are formed and the boards are cut at both ends before being fed layer by layer to a stacker.

Kallfass Abblätterer, peel-off system

Separated logs are transported to the Kallfass peel-off system to create layers of boards.

Adequate capacity

Kallfass collects the side boards in buffer levels. “As we had little experience with these short dimensions, the design was partially based on assumptions that, ultimately, worked out very well indeed”, reported Kallfass Project Manager Matthias Link.

Solution-oriented approach

This was neither the first nor the last joint project for Kallfass and Juodeliai. The German plant engineers had already been involved in a greenfield project for the Lithuanian timber industry in 2014. “We’re delighted to have opted again for Kallfass. They never try to offer us prefabricated solutions, but rather concentrate on our ideas and implement these. This practical approach is the main reason we decided to work with Kallfass again”, emphasised Andrius Zimnickas, adding that the next project, a second main product stacking system for Marijampole, has already been commissioned. This will be commissioned in the 1st quarter of 2024 at the latest.

Holz Imprägnierung, impregnation of wood

Application of an impregnation agent

Kallfass Abblätterer, peel-off system

Separated logs are transported to the Kallfass peel-off system to create layers of boards.

Sortierförderer, sorting conveyor

Kallfass sorting conveyor for ejecting unsuitable products.

Pufferetagen mit Seitenware, buffer levels with side products

Side view of the products buffered in 4 levels.

Versandpaket mit Kufen und Umreifung, shipping package with strapping and supporting runners

The completed shipping package, with triple strapping and supporting runners.

Images: Kallfass, text: Günther Jauk, Holzkurier

Holzkurier 17/2022

Zaunpfähle anspitzen, Gehrungsschnitt

Vom Schnittholz zum Gartenholz EN From sawn timber to garden timber

Whether for a terrace, privacy fence or a raised bed, hardly any garden can do without wood. The demands associated with the production of garden timber are as varied as the raw material itself. Sawmills which, in addition to standard timber products, also include a special garden timber range in their portfolio, need a plant configuration that can combine classic machining steps flexibly with special refining processes.

Kallfass provides turnkey mechanisation concepts for further processing of timber, integrating profile milling for chamfering fence battens, planing machines for rippling of decking, incisor systems for preparing material for impregnation and chop saws for fence post pointing.

The following practical example of the installation of a fence production line in a confined space involves the raw material travelling from the vacuum destacker to a multiple cross-cut saw to create the required lengths. It is then conveyed on to the post pointing plant for sharpening of fence poles and subsequently passes through a profile miller for chamfering or milling of a radius on the board head. The squared timbers are now separated, planed and bundled, followed by a stacking and strapping system. This is only one installation example of many. Quality assessment systems, equipment for labelling and marking and incisor systems can be included in the configuration if desired.

Processing from sawn to garden timber often involves a lot of time and personnel. A well-conceived, automated production concept reduces manual tasks to a minimum and multiplies the production output.

Squared timbers are turned while passing through and pointed with a mitre cut on 4 chop saws to create fence posts

Milling of a radius on the board head

Holzkurier 09/2022

Emptying sorting box

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

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

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.

Vertical Box Sorter

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

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.

Stick placement with magazines

Stick magazines for automated placement of dry sticks on stacking layers

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.

Assessment chain conveyor_measurement

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

Feeding box sorter

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

Emptying sorting box

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

Unscrambling_Separating

Unscrambling of batches following emptying for subsequent formation of layers

Multiple cross-cut saw

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

Stick placement with magazines

Stick magazines for automated placement of dry sticks on stacking layers

Hobellinie Van Roje, planing line, ligne de rabotage

Flexibles Hobeln kleiner Chargen bis 8 m Länge EN Flexible planing of small batches up to 8 m in length

Holzwerke van Roje installs a new planing mill in its existing facility at the Oberhonnefeld-Gierend location (Rhineland-Palatinate).

Holzwerke van Roje strengthened its own finishing with the installation of an automated planing mill last year. Connected to the sawmill, around 50% of the main product is processed further here. The company invested around 3.7 million euro for this purpose in the new plants.

Satisfied with the cooperation and results of the project (from left): Planing Mill Manager Eduard Dück, the Managing Director of Holzwerke van Roje, Gerhard Hauschulte and Kallfass Director Hans Haist.

Holzwerke van Roje GmbH & Co. KG operates a sawmill at its Oberhonnefeld-Gierend location (Rhineland-Palatinate) with an annual timber output of around 450,000 solid cubic metres. 90 % spruce and 10 % Douglas fir are currently processed, but Managing Director Gerhard Hauschulte estimates that pine will be added to this again to ensure the availability of timber logs in future. A planing mill and pellet production facility producing 80 000 t per annum are attached to the saw mill, and a cross-laminated timber production facility is currently under construction. Holzwerke van Roje currently has a workforce numbering 160 employees.

The planing mill was completed last year as a completely new installation at the plant and adapted to meet the special needs of sawmill production. The objective is to clearly strengthen processing of sawn timber. Up to 70,000 m³ of planed workpieces will be produced per annum from the main product, which is equivalent to about 50 % of the main product produced in the sawmill.

Kallfass GmbH in Baiersbronn delivered the complete fully automated mechanisation technology for the new Rex “Big Master” planing machine from Georg Schwarzbeck GmbH & Co KG in Pinneberg, including a wrapping station. A cupping and moisture meter, a “Golden Eye” quality scanner from Microtec, a marking station from REA JET and the strapping unit from Fromm are integrated in this facility.

Hobeleinzug, Planer Infeed, chargement de raboteuses

Kallfass planing machine feeder

Einzug REX Big Master Hobelmaschine

Infeed side of the REX “Big Master” planing machine

During conversion planning in April 2020, the two existing planing lines were dismantled in June of last year. Kallfass began at this time to install parts of the mechanisation technology in cleared areas of the facility while production was still underway. Commissioning of the complete plant then followed at the beginning of September. The plant was producing around 400 m³ of planed workpieces a day in 2 shifts by the end of the year.

Production at the van Roje sawmill is very customer-oriented, serving buyers all over Europe. There is a focus on markets in the Netherlands and United Kingdom with the majority of orders for lengths exceeding 6 m. Van Roje has also concentrated on the European market in recent years, exploiting domestic sales opportunities freed through the booming US sawn timber market. Stock dimensions up to 620 mm and log lengths of 3 to 14 m are cut. The maximum length in the timber sorting system is 8 m. Frequent product changes of up to four times an hour are part of everyday production at van Roje. This means that, when it comes to the cross section and length, a broad variety of dimensions is encountered in the planing mill, and it is necessary to work with relatively small batches. The smallest batches frequently involve only two packages per dimension. The planing mill therefore needs to be very flexible and produce everything from roofing battens with numerous special dimensions to raw solid structural timber. The maximum dimensions of completely planed products at van Roje are 150 x 320 mm. In particular, the maximum possible length of up to 8 m means the plant differs from the majority of industrial planing mills.

Minimum adjustment times and “profile management” on the planing machine

The flexibility required at van Roje is reflected in the configuration of the Rex “Big Master” planing machine: With ten planing cutterheads (four horizontal and two vertical tools and four individual chamfering tools for an all-round workpiece chamfer) finished product widths of 60 to 400 mm and heights of 15 to 200 mm can be created with continuously adjustable feeds of 30 to 150 m/min. In addition to planing and profiling, single and multiple cutting to length of the workpiece is also possible, and van Roje uses up to five saws.

Different board widths can be processed in layers simultaneously on the machine with only narrow gaps between them. Width adjustment is servo controlled at an adjusting speed of 20 mm/s. The Rex profile management control system enables storing of working shaft positions which have been configured. If a particular profile needs to be repeated, the operator, after deploying the required tools, can select the profile using the assigned workpiece name. The machine then automatically moves each spindle into the correct position. Shafts not required for a procedure go into idle mode, leading to a palpable reduction in the electric power input.

Hobelline, Planing line, ligne de rabotage

Schematic depiction of the van Roje planing mill. The material moves from charging and tilt destacking via a sorting conveyor to the Kallfass planing machine feeder. A triple cross-cut saw is installed upstream. A Microtec quality scanner (1) is installed behind the Rex planing machine. Options then available are a bundling station (2) and marking station (3), after which the product is transferred to the wrapping and strapping station (6) by one of the two stackers (4 and 5). The packages are output to the right onto the acceptance point in front of the plant (7). Ejection of material from the sorting conveyor is possible (8).

Compact mechanisation for workpiece lengths up to 8 m

Kallfass installed a fully automated mechanisation solution here with an interface connection to the van Roje ERP system (Timbertec). With regard to operation of the planing mill, aside from the plant operator and a stand-in, only two other employees are required for wrapping.

Following tilt destacking of the raw material packages (presorted in the sawmill in the case of freshly cut material) and separating, unsuitable material can still be ejected from the sorting conveyor prior to planing machine charging. The plant can therefore also be used for stacking of drying packages. A growth ring detector (cupping detector) integrated on the unscrambler and a moisture meter from Microtec combined with a board turner contribute to the improvement of planing quality. Timber that is too moist can be ejected and raw material turned, depending on the growth ring position.

A freely positionable triple cross-cut saw is installed upstream of the planing feeder and frequently used at van Roje. Cutting upstream of the planing machine achieves absolutely fringe-free cuttings. The feeding of the planing machine achieves 50 cycles/min. Directly downstream of the planing machine, the workpieces pass through a “Golden Eye” scanner from Microtec that organises the product into strength classes C16 and C24. They can then be separated from each other in the passage and either sent directly to one of the two stackers or, previously, to a bundling unit. Adaptation of CE certification for mechanical sorting is currently underway at van Roje. The customer can therefore be offered a combination of mechanically and visually sorted planed workpieces.

Four strapping stations are available at the bundling unit. Up to ten stick bundles can be created there every minute. Packages can be produced on stackers equipped with stick magazines at a rate of 10 layers/min.

Flexibility and rapid dimension changes are core requirements of mechanisation at van Roje, given the frequent product changes involved. A dimension change upstream of the planing machine takes around 1 minute under practical conditions and 20 seconds downstream of the planing machine, meaning each dimension change takes a total of 1 to 2 minutes. The entire mechanisation is designed to provide a feed of 200 m/min. The compact mechanisation layout can accommodate timber lengths of 8 m with ease, while the minimum length for raw material is 2.00 m and 1.80 m for planed products. Package lengths up to 8 m can also be wrapped on the package wrapping unit.

CLT marketing from May

The planing mill is not only designed for finishing the main product, but also represents an important downstream production section for the cross-laminated timber production facility under construction. B sorters for lamellas originally created in the sawmill for other products are calibrated and quality sorted here for use as top layer lamellas in cross-laminated timber (CLT). Lamellas cut especially for the top layer in the sawmill are planed directly in the cross-laminated timber plant. Raw lamellas created from side products are planed and quality sorted for use as (non-dovetailed) transverse layers in the CLT. The option to create different board widths in a layer on the planing machine really pays off here. Exploitation of side products can therefore be considerably increased.

When compared to the usual contemporary production process in CLT manufacturing, the entire production process is to be optimised for resource efficiency, from production of raw lamellas in the sawmill to the completed CLT construction element. Particular attention is also paid to the conservation of raw materials in the cross-laminated timber plant (which bears the project name “Cross Works”). Window and door cutouts are returned to the raw materials cycle again through a treatment process. The cutouts created are separated and recycled in the cross layer. These efforts to achieve resource efficiency have also encouraged support of the overall project through funding of EUR 5,993,815 from the environmental innovation programme of the German Federal Ministry of the Environment. 75,000 m³ CLT should be manufactured annually as of April in 2-shift operation. van Roje wants to begin marketing its cross-laminated timber in May.

Hobeleinzug, Planer Infeed, chargement de raboteuses

Kallfass planing machine feeder

Einzug REX Big Master Hobelmaschine

Infeed side of the REX “Big Master” planing machine

Hobelline, Planing line, ligne de rabotage

Schematic depiction of the van Roje planing mill.

Kippentstapelung, tilt destacking, dépilage par renversement

Charging and tilt destacking from Kallfass.

Bündelung, bundling, bottelage

The view into the front part of the van Roje planing mill facility. The bundling unit is in the foreground, with the feed for the first stacker behind. Visible in the background are (from the right) the sharpening center, the noice-protection cabin of the planing machine and the “Golden Eye” scanner.

Bündelung und Stapler, bundling and stacking, bottelage et empilage

The rear part of the facility, with the bundling unit in the foreground again and the line with the second stacker behind.

Graphics: Kallfass / Images and text: J. Härer, Holz-Zentralblatt

Holz-Zentralblatt Nr. 3/2022

Zuführung Schnittholz aus Sägelinie, feeding timber from saw line

Flexible Sortierung EN Flexible sorting

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

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

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

The best concept

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

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

Wolfgang Kolb, owner of Sägewerk Kolb

Vermessung Schnittholzdimensionen, measuring timber dimensions

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

Befüllung Schrägboxen, Charging of inclined boxes

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

No worker needed for the side products

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

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

Stacking of the main product is also automated

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

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

Zweite Zuführung von Schnittholz in die Fertigung, second feeder of timber to production

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

Projektteam Kolb und Kallfass, project team Kolb and Kallfass

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

Mehrfachablängsäge mit vier Sägen, multiple cross-cut saw with four trimmer saws

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

Visuelle Qualitätskontrolle von Schnittholz, visual quality control of sawn wood

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

Visuelle Qualitätskontrolle von Schnittholz, visual quality control of sawn wood

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

Images and text: Martina Nöstler, Holzkurier

Holzkurier 47/2021

Visuelle Qualitätskontrolle von Schnittholz

Für alle Dimensionen gerüstet EN Equipped for every dimension

Planing unit no. 5 has been in operation at Rettenmeier Holzindustrie in Ramstein, Germany since April. During the design phase, those responsible placed enormous importance on achieving a high level of flexibility, as Rettenmeier specialises in particular in supplying DIY stores.

The goal of Rettenmeier Holzindustrie is to increase added value in the company. “That’s why we invested in a further planing line in Ramstein”, explained Rettenmeier CEO Dr. Stephan Lang. He indicated that timber production in Ramstein is 600,000 solid cubic metres per annum in two shifts. The capacity of the planing units is about 200,000 m³ per annum. The sawmill group distributes around 35 % of the products it produces in the DIY sector. 35 % goes to the specialist German and international trade, 20 % to the industry and packaging sector and 10 % involves sawmill by-products.

Hobeleinzug, feeding of planers

Rettenmeier CEO Dr. Stephan Lang and Kallfass Managing Director Hans Haist (from l.) in front of the planing machine feeder.

Rapid output achievement

Those responsible primarily focused on flexibility and, simultaneously, a high level of availability with regard to the new planing line. For this reason, mechanisation was entrusted to Kallfass in Baiersbronn-Klosterreichenbach, Germany. “We knew Kallfass would supply the solution we wanted”, Lang emphasised. The mechanisation specialist had already converted an existing planing line in Ramstein, and this worked out perfectly. In retrospect, Lang is more than satisfied with handling of the project. “I’ve rarely experienced such a perfect commissioning. We achieved almost 100 % output after four weeks, and 6000 m³ of battens had already been bundled in this period. If we had to, we’d construct the plant in the same manner again”.
Kallfass adapted the new planing line to fit an existing facility exactly. The plant can process lengths ranging from 2 to 5 m, widths of 60 to 300 mm and thicknesses of 14 to 120 mm. Issues relating to available space mean the vacuum lifting device destacks the dried timber packages in layers. A stick stripper brushes the stacking strips down and conveyor systems collect these. An operator initially assesses the workpieces visually in the transverse transport. Following this, they are checked with a Brookhuis moisture measuring. “Unsuitable timbers can still be ejected here”, explained Kallfass Managing Director Hans Haist. Kallfass subsequently installed the longitudinal feed in the direction of the WJS planing machine. Depending on the timber length, this can achieve up to a maximum of 80 cycles a minute.

„Kallfass handled the entire project impeccably. We achieved almost 100 % output within four weeks.“

Dr. Stephan Lang, CEO of Rettenmeier Holzindustrie

Zwischenlagerung Schnittholz in Filmetagen, temporary storage of timber in film layers

Unsuitable dimensions can be stored temporarily onto a conveyor in film layers and then fed into the production process again.

Resorting for higher quality

There are two options downstream of the planing unit. Timbers that can be classified as a higher quality through cutting are sorted out to the left onto a conveyor in film layers. These can be fed into the process again if, for example, a dimension change occurs in the planing machine. “This resorting dispenses with the need for a further stacking system and complex trimmer station”, said Haist. The majority of planed workpieces are pulled onto a cross conveyor behind the conveyor with the temporarily stored film layers. An operator examines the workpieces here, ejects timber pieces of unsuitable quality and, by drawing on the timbers, can determine the chop cuts. In addition, Rettenmeier opted for a bundling system. In the case of single pieces, this simply involves “running over” these with transport chains. Kallfass also integrated a labelling system in this section. Kallfass was already involved in the development of this solution at Cordes, and it is also employed in Ramstein. “Both the bundles and wooden strips can be labelled”, explained Haist.

Following this, the timbers pass through the tried and trusted multiple cross-cut saw from Kallfass. The saw is equipped with four variable saw aggregates. The layers are then transferred to the stacking system which is equipped with magazines with automated stick placement. The stacker is also suitable for DIY packages (i.e. quarter packages). Finally, the finished packages are foil-wrapped and prepared for shipping. When it comes to foil wrapping, Kallfass provided yet another machine that mills the grooves in squared timbers. “This has proven its worth on numerous occasions”, said Haist.
“The new planing line allows us to achieve classic four-sided planing and, also, separation, or simply tongue and groove sections. That makes us extremely versatile. Kallfass provided us with a simple, but extremely efficient solution that allowed us to cover all requirements”, Lang confirmed.

Holzsortiment

Rettenmeier processes four types of timber in Ramstein (including Douglas fir) to create products for the construction industry and specialist trade.

Leistenabstreifung mit Leistenbesen, stick stripping with brush

Following destacking in layers with a vacuum lifter, a stick stripper brushes the stacking strips down.

Visuelle Qualitätskontrolle von Schnittholz, visual quality control of sawn wood

A worker examines the workpieces and can realise chop cuts by drawing on the timbers.

Bündelungsanlage, bundling unit

Kallfass also provided Rettenmeier with a bundling system complete with marking station…

Mehrfachablängsäge mit vier Sägen, multiple cross-cut saw with four trimmer saws

… and the tried and trusted multiple cross-cut saw with four saw aggregates.

Leistenmagazine zur Holzleistenlegung, stick placement via magazines

Hans Haist and Stephan Lang observe stick placement and the stacking of packages.

Images and text Martina Nöstler, Holzkurier

Holzkurier 38/2021

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