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.

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

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

Mechanisierung Upgraded

Mechanisierung upgraded EN Mechanisation upgraded

More flexible and quicker production through automation

Quicker, easier, more flexible. These are all requirements which a modern timber production facility designed for different product dimensions needs to meet. The focus on the product needs to change to a focus on the process to achieve this, as processes can be actively influenced.

Kallfass, the automation specialist from Klosterreichenbach/DE, analyses the customer’s production goals and framework conditions that define the automation level of the plant. After all, the ratio between sawmill capacity and the extent of investment must be exactly right.

Robot versus personnel costs

Potential upgrades which can be exploited in automation include the use of a robot to take the place of pick & place handling which otherwise involves a high level of human resources. In the case of production involving large batches per timber dimension, this investment can pay off very quickly in the form of savings in personnel costs.

Kallfass has offered a fully automated stick handling system since last year. Time-consuming filling of the stick magazine is realised by a robot that accomplishes charging with practically no human intervention and at a consistent cycle rate. In addition, a stick scanner can be used prior to magazine filling that assesses the quality of the sticks. Only suitable sticks are separated, packetised and then prepared for robot filling.

Roboterbefuellung_Leistenmagazine

Robot solution for automated filling of stick magazines

Holzkurier 34/2020

BSP Prozess Know-How EN CLT process know-how

SINGLE PROVIDER FOR EVERY SOLUTION
The topic of cross-laminated timber has become increasingly significant in contemporary timber construction. CLT production is complex and requires extensive space. With plant sizes of up to 200 m in length and 80 m in width, planning frequently has to begin in the “great outdoors” and include the production facility.

Kallfass, the machine manufacturer from Klosterreichenbach in Germany’s northern Black Forest region, regards itself as a solution provider, taking charge of complete project planning for its customers. Production lines, ranging from plants for finger jointing of timber lamellas to single-ply boards to the gluing and pressing of single-ply boards to create cross-laminated timber boards, have already been realised in a variety of configurations in Germany, Austria and Scandinavia. Many years of process experience enable Kallfass to minimise interfaces in its fully automated mechanisation, combining all components to create a highly efficient production line.

The Kallfass CLT press is the latest addition to the range. Development concentrated on achieving a high degree of product precision and quality and reliable creation of a zero joint, regardless of the product dimensions involved.

Available at an attractive price, the Kallfass CLT press combines single-ply boards measuring 8 to 20 m in length to create multi-layer panels

A hydraulic concept based on quasi-isobaric pressing that enables the generation of both vertical and transverse pressure is at the core of the Kallfass cycle press. Pressure control ensures a constant pressing force of at least 1 N / mm² over the entire board surface, even where a maximum board width of 3.6 m is involved. Combined with quick-bonding polyurethane adhesives and fully automated charging / emptying, this enables the achievement of short cycle times and maximum production capacity.

Massanzuege Aus Metall

Maßanzüge aus Metall EN Bespoke tailoring in metal

Kallfass is an enterprise from Wernigerode that constructs plant for sawmills all over the world. Targeted revenue for this year is 23 million EUR.

Kallfass GmbH – Maschinen plus Automation in Wernigerode has made its mark on the global market. Located in the Harz, the subsidiary of the parent company in the Black Forest community of Klosterreichenbach constructs special machinery for processing sawn timber. These plants are installed all over the world. The company aims to achieve a turnover of 23 million EUR for the first time this year. After delivering a completed plant, the production facility in the Stadtfeld industrial park can appear pretty manageable at first glance. Indeed, it is hard to imagine that plants often measuring 100 metres in length, 20 metres in width and 10 metres in height are manufactured here for use all over the world.

… Carefully packed, many plants have set out from Wernigerode on the journey to their new destination. Some made their way to Austria, while other machines were also delivered to Sweden. Specialists from Wernigerode were also responsible for constructing a plant in South Africa. Kallfass is not simply a hardware provider. It also takes care of on-site plant construction.

… All plants, including those already assembled, also need to be serviced at regular intervals. This machinery from the Harz is definitely not an off-the-peg solution. Each plant is, in its own way, a “Rolls Royce”, says Enrico Goldhahn (Operations Manager at Kallfass GmbH in Wernigerode). Each plant is completely unique, including those fully automated solutions which, in this age of Industry 4.0, the company finds itself increasingly constructing and installing. One merely needs to enter a code here, and the machines adapt and adjust to suit the respective product. “Sometimes we construct really large plants, and then – and only then – is the factory built to house them. We’re making, so to speak, bespoke suits in metal.

… We’ve made a point for years now of ensuring that we can always rely on a steady supply of young highly qualified talent”, explains Goldhahn, pointing out the training results of his apprentices. These are consistent in their excellence, so it comes as no surprise that the skills of Kallfass personnel and Kallfass plants made in Germany enjoy an excellent reputation all over the world.

… The export share is generally around 75 %. Solutions are realised for clients all around the globe, with customers in North and South America, France, Scotland, the Netherlands and even Australia.

… The next plants will be installed in Austria, Lithuania and Switzerland. A sorting machine here, a planing unit there, and a stacking line over there. And Russia is also a popular destination. It is an extremely significant market, a fact reflected in the order books. These are filled for the next 18 months with commissions.

Forecasts clearly indicate that future expansion can be expected at both the parent company in Klosterreichenbach in the Black Forest and the Wernigerode location in the Harz. In the Black Forest, the company has just grown through the acquisition of an additional facility. Consideration is also been given to expanding capacities in the Harz. Throughout Europe, the machine manufacturers from Kallfass are number two in their sector

 

Text Frank Drechsler, Harzer-Wirtschschaftsblatt September/Oktober 2019