2021 – Kallfass

Zuführung Schnittholz aus Sägelinie, feeding timber from saw line

Flexible Sortierung EN Flexible sorting

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

The best concept

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

No worker needed for the side products

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

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

Stacking of the main product is also automated

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

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

Visuelle Qualitätskontrolle von Schnittholz, visual quality control of sawn wood

Für alle Dimensionen gerüstet EN Equipped for every dimension

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.

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.

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.

Kallfass Sonderlösungen für Deckenelement-Werk

Leimholzwerk spielt alle Stücke EN Glued timber plant has it all

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.

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.

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.

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.

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

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.

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”.

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.

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.

Automatisch im Vorteil EN Automatic Benefits

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.

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.

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.”

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

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

An enormous feat

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

Clean sorting

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

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

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

Boxes up to 30 % larger

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

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

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

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

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

Successful project

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

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

Kontinuierlicher Zufluss
mit Leistenroboter EN Continuous inflow with stick robot

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.

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.

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.

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

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

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

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

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

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

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

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

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

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

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.

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

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

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

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

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

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

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

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

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

Multi-storey production for multi-storey timber construction

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

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

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

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.

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

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

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

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.

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

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

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

Foil wrapping, strapping, packet note – everything compact

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

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

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

Marking at full speed: units supplied by REA Jet

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

Automatic package squared timber stacking

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

“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."

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

The robot sticking machine in action

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

Installation of the new line began in June 2020

Smart, clean and safe

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

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

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.

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

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

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

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

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

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

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

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

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

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

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

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

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