Expansion of the sorting system as part of the big investment plan
Thirteen years ago, Bois Du Dauphine (B.D.D.) suffered a heavy blow when a fire destroyed the production. Today, the sawmill is one of the foremost timber industries in France. Those responsible prepared an extensive investment package until 2024, including the expansion of the sorting system.
The family-run Bois Du Dauphine is located in the Alpine region between Grenoble and Chambéry, France. Founded in 1983, the company was originally a forestry operation. In the meantime, a timber industry has developed in Le Cheylas, France: B.D.D. operates a sawmill, and the neighbouring sister company A.E.B. produces pellets, heat, and electricity. In keeping with the saying, “stagnation is regression”, those people responsible have devised a sensible investment strategy for 2022 to 2024. The objectives are clearly defined:
- Increase in cutting capacity by approx. 25 %
- Improving the yield by 3 % based on more accurate defect detection, precise cuts, and sorting in several boxes when the length is distributed from 2.5 to 6 m in 50 cm increments
- Additional increase in yield to be achieved by doubling the number of side products
- Increasing the capacity in the pellet plant and stabilising power generation in the winter season
Pleased with the successful expansion of the sorting system made possible by Kallfass: Bertrand Jurdic (Technical Manager), sawmill manager Sylvain Mangournet, and Frédéric Hiegel (conversion project manager) at B.D.D. (from left to right)
New sorting system in operation
In September of 2022, B.D.D. was able to complete one of these investment steps: Kallfass, Baiersbronn, Germany, installed and expanded the sorting system, including the wood package and strapping system.
First, Microtec installed at B.D.D. a Goldeneye scanner to replace an existing one. When using the downstream trimmer saw, which was subsequently installed by Kallfass, undesirable wood features can be effectively removed. Thereafter, the sorting takes place: In the past, B.D.D. separated all sawn timber (main and side products) using 25 sorting boxes. In order to expand the system, Kallfass added 50 more inclined boxes. According to Kallfass, the charging system can output 160 pieces per minute. The board cross-sections range from 12 x 60 mm to 100 x 250 mm, whilst the lengths vary from 2.4 to 6 m.
The boxes are emptied downwards onto a long buffer chain conveyor. After the boards have been separated, they pass in layers through a multiple cross-cut saw with seven saw aggregates.
The sawn timber is now sorted according to length and cross-section in 75 inclined boxes – previously B.D.D. sorted the main and side products in 25 boxes
Subsequently, the boards are transferred to the stacking unit, where 16 layers per minute can be produced. B.D.D. opted for the Kallfass stick placement system, which comprises seven adjustable double magazines. This design allows thin sticks (14 x 25 mm)—that were previously intended to be disposed of—or thicker kiln sticks (25 x 50 mm) to be used.
“Now, this system allows us to produce different packages”, explains Bertrand Jurdic, Technical Manager at B.D.D. The package sizes range in width, height and length from 1,000 x 450 x 900 mm to 1,200 x 1,400 x 6,000 mm.
The finished packages enter a swivelling package discharge system, which changes from the transverse to the longitudinal direction. The strapping station, made by Fromm System GmbH, is supported by a layer of squared timber. In addition, Kallfass will supply an extended aligning roller conveyor, thus increasing the buffer area.
For its stacking system, B.D.D. opted for seven double stick magazines from Kallfass
Kallfass completed the modification effort in the summer, requiring about three and a half months. “We only required three weeks of downtime for the saw line during this time, in order to connect the new sorting system to the existing plant from 2010”, Jurdic explained. Kallfass delivered the steel and mechanical parts for the project using 13 lorries. B.D.D. decided to use a wooden construction method for the new hall.
The entire preliminary discussions, consultation, development, and handling of the project were organised by Hans Haist, Managing Director of Kallfass when he interacted with Jonathan Bleesz of VBI (Kallfass' representative in France). “When we expanded the sorting system, we were able to achieve an important step in our expansion plans”, says Jurdic.