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, visual quality control of sawn wood

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

Schrägboxensortierung

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

Smart, clean and safe

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

The main product, predominantly 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.

Gelo Boxensortierwerk

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

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.

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

Wolf-Christian Küspert, Managing Director GELO Timber

Boxes up to 30 % larger

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

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

A worker can even assess the quality of both 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.

Vereinzeler

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

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

Eintaktung mit Tongloader

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

Mehrfachablängsäge mit vier variablen Sägen

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

Leisten-Doppelmagazine

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

Gestapeltes Schnittholzpaket

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

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

Kontinuierlicher Zufluss
mit Leistenroboter EN
Continuous inflow with stick robot

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

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

Flexible solution

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

Geschäftsleitung Kallfass mit Projektleiter von Sägewerk Egger

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

Two lines, three robots

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

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

Jens-Michael von Werder, responsible for production technology

Andrea, Hubertus and Paul

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

Zuführung Stapelleisten in Richtung Scanner

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

Leisteneintaktung Hauptware

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

Zusammenfassung Leisten

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

Leistenmagazine

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

Befüllung Leistenmagazine mit Roboter

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

Stapelpaket mit Stapelleisten

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

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

Kallfass-Hegener_Zufuehrung-von-Saege

Flexibilität auf eine neue Ebene gehoben EN Flexibility raised to a new level

Hegener-Hachmann Sawmill

The 12 October 2019 saw commissioning of the new sawmill at Hegener-Hachmann. This involved probably the most flexible production processes every realised in a medium-sized sawmill enterprise, posing a planning and technical challenge to all involved.

“Hanxleden 4.0 online sawmill – innovative, resource-efficient sawmill concept for SME” was the project title of the approx. € 11 million investment made by Hegener-Hachmann, Schmallenberg/DE. The new construction took exactly a year from October 2018 to October 2019. After a further twelve months, the planned cutting volume has, in terms of figures, been achieved – but right from the outset.

Hegener
Kallfass-Hegener_Sortimente-gemischt

Exploiting as many resources as possible

Hubertus Hegener-Hachmann heads the company in what is now the fourth generation. He receives significant support in this role from Markus von Weichs who, as his business partner, is primarily responsible for purchasing logs. Having started as a forestry business with an originally small sawmill as a sideline, Hegener-Hachmann had a used head saw and a circular saw when he invested in the first expansion in 2007. “We decided in favour of a completely new construction to ensure the sustainability of our business and, insofar as possible, to be able to cut a broad variety of log types, including in part from our own forestry. Among other things, this enabled us to continue production independently at the location during the production phase. Our goal is to ensure careful and effective use of the resources used during the entire production process”, says Hegener-Hachmann. “We want to process everything at a single location. As a medium-sized enterprise, we can only continue to exist on a broad basis”. What he means by this is not only classic sawn timber such as the raw material for solid structural timber, construction timber or landscaping timber. Hegener-Hachmann is well known in the region for his solid wooden flooring consisting of hard and softwood that goes by the name of “Gutshofdiele”. Larch, Douglas fir and Norway spruce are also processed.

As the entire endeavour is regarded as somewhat of a supra-regional flagship project in terms of flexibility, efficiency and conservation of resources, it received ERDF funding from the Ministry for Environment, Agriculture, Conservation and Consumer Protection of the State of North Rhine-Westphalia as part of the “Ressource NRW” call for projects. This covered 50 % of the components eligible for funding.

What has been created is a modern sawmill with a planned annual cutting capacity of at least 40,000 m³ for soft and hardwood. This has proven highly complex in terms of the processes involved. When it came to the cutting technology, Hegener-Hachmann chose an inclined log bandsaw with a chipper-canter for logs up to 10.5 m in length and with a diameter of 1.3 m. Around 70 % of the timber comes online from the log yard for cutting without presorting. Hegener-Hachmann placed his trust in the know-how of Kallfass (in Baiersbronn, Germany) when it came to mechanisation and the sorting and stacking system. “Aside from the economic viability of the investment, what was decisive for us was the supplier we placed our faith in to accompany us on this journey. The Kallfass solution also impressed us very much, and the company gave us a commitment to realise the project within the estimated time” reasoned Hegener-Hachmann. “Online cutting and the wide variation in product dimensions posed major challenges for us”, remembers Kallfass Managing Director Hans Haist. Kallfass also provided the control unit for the sorting system. “The demanding timbers and varied dimensions meant our programmers were faced with a difficult task“, explains Haist.

A lot of things are possible

The log is in all cases precut on the bandsaw and, following trimming, conveyed on to the Combimes BNK and/or head saw in the Kallfass sorting and stacking plant. However, two other options are also available: “Products with a length exceeding 6 m and a thickness of more than 105 mm, blocks or individual high-quality pieces can be conveyed into special discharge 1 on the head saw or special discharge 2 behind the BNK. These can then be lowered with care to the lower level using a hoisting unit”, explains Hegener-Hachmann. 

50 boxes and multiple occupancy

Timbers with a thickness of up to 105 mm, a width of 300 mm and a length of 6 m are fed into the Kallfass sorting system at Hegener-Hachmann. 50 inclined boxes are available here. With inclined boxes, the timber slides down more gently onto the chain conveyor during emptying. This is primarily an advantage where hardwood is involved. “Due to the enormous diversity of our products and the numerous wood types involved, the computer frequently assigns three different types to a single box if necessary”, says Hegener-Hachmann. In this case, the box is emptied when the filling level is reached and the dimensions which are not required are fed once again over a return run and sorted anew.

The timbers to be stacked are separated and assessed again by a worker with regard to quality in the transverse run-through. Inappropriate workpieces can be ejected or shortened here again. The boards are then fed through the Kallfass CNC multiple circular cross-cut saw. This cuts the timbers with zero and four variable saws, depending on requirements. “Cutting is perfect and realised with millimetre accuracy”, confirms the operator. This is followed by layer formation and packet assembly. Haist estimates the output to be up to ten layers or 60 boards a minute during cycling in. The packing system is equipped with eight magazines with automatic stick placement.

Finished packages are lowered using a hoisting unit. Space conditions mean that they are deposited on a roller conveyor located on one side. This pivots the package (which is on rails) through 90°. The package is then strapped and prepared for shipping. Half packages or packages that need to be unpacked without sticks after drying can be picked again using the connected tilt stacker during a renewed passage through the stacking plant.

Both the Hegener-Hachmann sawmill and Kallfass confirm their satisfaction with implementation and commissioning. The focus now is on ensuring together the continuous improvement of in-house processes and the data flow.

Kallfass-Hegener_Zufuehrung-von-Saege

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

Kallfass-Hegener_Sortimente-gemischt

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

Hegener_Beurteilung

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

Hegener_Crosscutting

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

Hegner_Paket-Drehung

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

Hegener

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

Hegener_Gutshofdiele

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

Neue Nachsortierung EN New re-sorting system

The Pfeifer sawmill in Uelzen has been in business for almost 30 years and, while timber production was originally around 200,000 cubic metres p.a., the anticipated volume this year is 500,000 m³. This enormous increase over the years means that bottlenecks are experienced at a variety of production stages. One of these was remedied around the turn of the year 2018/19.

The Pfeifer Group sawmill in Uelzen/DE is primarily involved in the production of packaging material and timber. “We’re a completely integrated location, utilising every product created at the site”, stresses site manager Marco De Gennaro in reference to the associated block production and CHP plant. Timber production has more than doubled since the mill was commissioned in 1991. The target volume for 2019 is 500,000 m³. The Pfeifer Group invests constantly to maintain its state-of-the-art technological capability and continuously enhance performance. A further step in this direction was taken in the autumn of 2018 when Kallfass (Baiersbronn/DE), specialists for mechanisation, installed a new sorting system for dry material. A re-sorting plant was already in operation Uelzen, but this had reached the limits of its performance. “We liked the Kallfass concept very much, and the company had proven to be a good partner”, explained De Gennaro. The new system is designed for a volume of 90,000 m³/p.a. “All our dry timber will run through this line in future”, says the site manager. He is particularly satisfied with the millimetre precision with which boards from 600 mm in length are cut, a point he emphasised in our discussion.

Sophisticated solution

The new dry sorting system enables Pfeifer to process raw material from 2.5 to 4 m in length. Karsten Gottschalk, project manager at Pfeifer in Uelzen, quantifies board cross sections at a thickness of 12 to 100 mm and a width of 70 to 250 mm. The generously dimensioned sawn timber discharge is suitable for either double packets with a width of 1.2 m or 2 m wide large packets. A tilt destacker separates the timbers in layers, whereby the stack battens fall automatically onto a conveyor belt. Kallfass installed an additional automatic batten collector for this purpose which, in effect, is a miniature sorting system. “As packets are often stacked in double layers, we separate the boards using a separation stage. In the case of single-layered packets, this can be passed over for a higher output”, explains Kallfass Managing Director Hans Haist during the tour. The boards pass by the operator in a transverse run-through, with the operator assessing them and ejecting substandard examples. This is followed by the tong loader that separates the board film. Kallfass guarantees a performance of 120 cycles per minute. A moisture meter measures the wood moisture. Material that is too moist is separated and dried again. The downstream Kallfass CNC crosscutting saw in Uelzen has four chop saws. This means that cutting with millimetre accuracy is possible as of a capping length of 600 mm. The stacking unit is equipped with magazines for automatic batten positioning. The finished packets are lowered using a hoisting unit where they are strapped and coated in film by an existing plant. The clean packets then stand on a roller conveyor ready for removal. Kallfass project manager Enrico Goldhahn summarises the advantages of the system: “No time is lost during destacking by the buffer, and just as little during packet assembly, thanks to continuous stacking with the auxiliary hoisting unit”. The new Kallfass re-sorting plant currently operates in two shifts. “But we can add another shift if necessary”, says De Gennaro.

Discharge: Kallfass installed a cross conveyor that provides space for several packets – then the process continues to the tilt destacker

Kallfass_Lattensammler

During separating in layers, the stack battens fall automatically downwards to the automatic batten collector.

Kallfass_Beurteilung

The boards run in the transverse transport past the worker who assesses them and, where necessary, ejects substandard examples.

Pfeifer-Kallfass_Lattenmagazin

Packet assembly and removal: Batten magazine with automatic stick placement.

Kallfass_Zuteilung

Individual cycling with tong loader: This has a capacity of up to 140 pieces a minute.

Kallfass_CNC-Crosscutting

The Kallfass CNC cross-cutting system enables cross-cutting of boards to the desired length.

Holzkurier 42/2019, pictures and text Martina Nöstler
Sortierung_Boxensortierung

Ausgezeichnete Ressourcenschonung und Innovation EN Excellent resource conservation and innovation

With an investment in a new sawmill, Hegener-Hachmann changes its production process and expands its cutting capacity
In the Hochsauerland District, in the east of North Rhine-Westphalia, Germany, a complete new sawmill is under construction. In the future this sawmill will also serve other SMEs as an example of how the use of round timber can be improved and the efficiency of sawmill production can be increased: The Hegener-Hachmann GmbH & Co. KG had submitted its investment project in April 2017 for the “Resource NRW” call for the promotion of small and medium-sized enterprises and received the funding decision in November 2017. The system will go into trial operation in October and will then be open to all interested parties for viewing.

Sortierung_Boxensortierung

Kallfass sorting system with 50 inclined boxes for triple allocation

The Kallfass multiple crosscut saw produces cutting lengths as short as 600 mm

-Excerpt from article-

System configuration

...

Kallfass from Baiersbronn, Germany, supplied the sawmill mechanisation and the sorting and stacking plant. The material to be cut travels at a speed of 60 to 80 cycles/min from the resaw or from the log band saw or the gang saw and can be transported via curve conveyors both to the stacking unit and to the sorting system. The aim is to send over 70% of the production directly to the stacking unit. Eine Mehrfach-Ablängsäge kann Schnittlängen bis zu minimal 600 mm erzeugen, für die Stapelung müssen Längen unter 800 mm allerdings mit einer Doppellänge in der ersten Paketlage abgestapelt werden. Die Stapelmaschine mit automatischer Lattenlegung bildet 8 bis 10 Lagen pro Minute.

...

The sorting system can handle a maximum width of 280 mm and a maximum thickness of 100 mm. The incoming timber is measured in a grid of 500 mm. The sorting system has a capacity of up to 60 cycles/min. There are 50 inclined boxes available, having a volume of 3 m³ each, which can be filled with up to three different widths. Subsequently, a re-sorting unit upstream of the stacking system, from which two widths of the timber are returned for sorting purposes.

...

The minimum cutting lengths of a multiple crosscut saw is 600 mm, however, lengths shorter than 800 mm must be stacked with a double length in the first package length. A stacker with an automatic batten laying function forms 8 to 10 layers per minute.

...

Lighthouse Project in North Rhine-Westphalia

...

The state government of NRW recognises the company as a nationwide lighthouse project (a model project that aims to have a signal effect for numerous follow-up projects). Visits are possible by arrangement with business partners Hegener-Hachmann and von Weichs. Commissioning of the sawmill is scheduled for mid-October.

.

Pictures Kallfass, Text Jürgen Härer, Holz-Zentralblatt, Issue 40.