Germany – Kallfass

Das Multifunktionswerk EN The Multifunctional Plant

Extensive planning

Dold Holzwerke has been producing planed timber and slats for decades. “Until now, however, our mechanisation around the planing machine was kept relatively simple. We decided to invest in a new planing mill in order to increase performance and efficiency”, explains Faller. However, due to the limited space available at the site, those responsible initially decided to build a new office building, as the old one was literally bursting at the seams. Initial designs for the planing mill started in 2020, with the ground-breaking ceremony for the new hall following in November 2022. In order to make the best possible use of the space, it was designed as a two-storey building: The sawn timber warehouse is located downstairs and the new planing mill is on the upper level.

Kallfass was chosen as the supplier for the mechanisation. “We spoke to several providers, but were ultimately convinced that only Kallfass could realise our extensive wishes. We have also worked with Kallfass before”, says Faller, who also emphasises the great project management on the part of the supplier. “During planning, we took into account the requirements of the market as well as the necessary dimensions and quantities. Our portfolio is very customer-orientated - we deliver what the customer needs”.

One type of wood - many possibilities

Kallfass has planned a highly flexible system in cooperation with Dold Holzwerke. Faller and Huber also refer to it as a “multifunctional unit”, as it is by no means limited to planing. Various operating modes are possible:

planing with and without multi rip saw
planing with and without bundling
pure restacking operation
bandsaw rotation with and without planing

The Kallfass system is designed for board lengths from 2 to 8.1 metres. The cross-sections range from 18 x 80 mm to large KVH (structural solid timber) cross-sections. “Due to the diverse operating modes and the wide range of dimensions, this project was anything but ordinary for us”, says Kallfass programmer Holger Seidt. Huber puts the annual capacity in two-shift operation at up to 90,000 m³.

The Kallfass mechanisation starts with a package feeder, using a hoisting unit that moves the package to the second level—with a possible total load capacity of 16 t— and a separate tilt destacking system. The drying chamber sticks and the waste sticks fall off automatically and are transported to a collection station. After separation, the wood can take two paths: The path either continues straight on to the Tongloader®, or the boards are transported upwards via a bypass and on to the Weinig Raimann twin bandsaw. This can be used to cut the pieces either horizontally or vertically. The band saw feed operates at a feed speed of 100 m/min.

Planing or restacking

Using the Tongloader®, the boards are loaded into the carriers, one-by-one. After the moisture and warp measurement, defective parts can be ejected. However, if these parts can be processed further, the pieces are placed in a stanchion, otherwise in the chipper. The next step is the tried-and-tested Kallfass multiple circular cross-cut saw with a fixed saw and two variable units. Downstream of this system, there are again two options: downwards into the bypass for pure restacking or straight on into the Kallfass planing infeed. This feeder is designed for a maximum feed speed of 250 m/min.

Behind the planing machine is another special feature: a Weinig Raimann multi rip circular saw for even more flexibility in production. Kallfass mounted this on rails so that it can simply be pushed to one side when not in use. The workpieces are then pulled off to the left onto the chain conveyor with the assessment station. Here, parts can also be ejected downwards. These either go to the second stacker or into the chipper. At this point, an employee is still present to inspect the quality. However, when configuring the system, care was taken to ensure that a scanner could be integrated into the process relatively easily, if required.

One of the reasons why Dold Holzwerke invested in the planing mill was to produce slats more efficiently. For this reason, Kallfass installed a bundling system. “We compile the bundles in terms of quantity according to customer requirements. The advantage of the Kallfass solution: From assembling the bundles to strapping them, the wood is fixed at all times”, Faller points out during the tour. The bundles or sawn timber are then packaged on one of the two stacking systems, transported downwards and fed to the strapping station made by Fromm. Kallfass has also incorporated a feature here: To make work easier for the employees, there is a hoisting unit in the roller conveyor that raises the wood package by at least 50 cm.

Since the plant was built in a new hall, Dold Holzwerke was able to continue production with the existing system. “Kallfass first put the entire mechanisation into operation. At the very end, we then installed the refurbished planing machine in its current location”, explains Huber and Faller concluded: “Thanks to the high level of automation and the quick changeover of the systems, we have hardly any downtime.

Ersatzinvestition “Deluxe” EN “Deluxe” replacement investment

Anyone looking for customised and innovative transport solutions will find what they are looking for at Bössl Paletten in Schönthal-Drosendorf, Bavaria, Germany. Quality and customer loyalty are firmly anchored in the self-image of the family business – and Bössl therefore places the same demands on its machine suppliers. After 1989, Kallfass was again chosen for the new cutting system – after 35 years of tireless use of the previous system.

Last year, Bössl produced almost 2 million pallets. Customised products and individual transport solutions accounted for over 70%. "Euro pallets and standard goods complement our portfolio, but are not the reason why customers around the world rely on us," explains owner and Managing Director Ottmar Bössl.

Bavarian success story

Bössl slipped into pallet production by chance: After its beginnings as a sawmill and the production of urgently needed construction timber for the German reconstruction, the company specialised in wooden drinks crates in the 1960s. When these were gradually replaced by plastic, Bössl utilised existing business relationships and developed into a leading Bavarian manufacturer of brewery and beverage pallets. “Back then, around 90% of our production capacity was accounted for by returnable beverage pallets – today the picture has changed fundamentally”, Ottmar Bössl looks back.

With the growing use of Euro pallets, Bössl had to find new niches. Today, he can proudly claim to have successfully found and filled those niches. In view of the large number of customers from the pharmaceutical, food and chemical industries, however, the question arises as to which niche this actually is – the company is at home in all industries from automotive to brick. “Everyone who demands quality at the highest level”, Ottmar Bössl answers confidently and adds: “In some areas, the market is developing towards high-quality products, reusable systems and special pallets for high-bay warehouses in food logistics. This is where we can fully utilise our strengths”.

The use of planed boards and blocks is therefore already the order of the day at Bössl. Hardwoods and multiplex boards have also been used in high-quality transport solutions for many years. Of the approximately 400 different products available today, around 20% are made entirely or partially from beech or, if desired, from other hardwoods and wood-based materials.

There was no question about the choice of supplier

The use of hardwood was also one of the reasons why the decision was again made in favour of a single board cutting system. “Beech cannot be processed in a package in terms of quality. Kallfass knows these requirements and has designed the system exactly according to our wishes”, summarises Ottmar Bössl.

Bössl has a long-standing partnership with Kallfass. The machine manufacturer delivered the first cutting system to the Upper Palatinate region near the Czech border over 35 years ago. This system was replaced by a modern system in 2024. “It was clear to us right from the start: Kallfass takes care of the cutting. Alternatives were not discussed – from our point of view, Kallfass is unrivalled in the premium segment”, emphasises Marco Bössl, who is the third generation to work in the family business

Precision in a confined space

“The existing hall didn't actually offer enough space for a new cutting system. In the end, it was a struggle for every centimetre”, explains Hans Haist, Managing Director of Kallfass. In combination with the tight schedule, the standard project quickly developed into a challenging task. “In the pallet business, it is not possible to produce in stock for a long time. Nevertheless, Kallfass managed to dismantle the old system and install and commission the new one within a few weeks. The schedule and budget were adhered to and our production remained almost completely undisturbed”, says a satisfied Marco Bössl.

The completely new system is only 17 metres long and is designed for timber lengths of up to 3.1 metres. The shortest board length is 595 mm. For timber with lengths of up to 5 metres, Bössl has another Kallfass system in operation, which was installed in 2008.

Kallfass installed the parcel pick-up station under a canopy in front of the hall to save space. After destacking in layers, the only employee on the line checks the timber quality and ejects damaged boards via the disposal chute below. These are immediately shredded and prepared for in-house transport to the wood chip plant. Alignment rollers ensure an exact zero line for each board before it passes through the five saw aggregates (four of which can be aligned automatically). Additional extraction systems directly above the saws ensure work safety and a clean working environment – a major advantage, especially when working with fine beech dust. At the end of the system, Kallfass installed an automatic empty pallet feeder. Like the stick magazines, these only need to be refilled once per shift.

Project according to plan

“This project shows: Even with standard systems, it's the detailed solutions that make the difference”, summarises Haist. For Bössl, the new investment is also a complete success: “The new system brings us enormous advantages: better cycle times, hardly any downtime due to faults and significantly reduced changeover times. This is a decisive advantage, especially for small series of less than 100 units”, explains Marco Bössl. His father adds: "I bought my first Kallfass system 35 years ago. A decision that I made again today and would make again at any time in the future.

Perfekt gekappt und gestapelt für Palettenfertigung EN Perfectly cut and stacked for pallet production

Bottleneck eliminated

Until now, Rückerl has used two cross-cut saws to cut the wood for pallet production. "That was very time-consuming and no longer in keeping with the times. In addition, cutting to size became a bottleneck due to the increasing quantities. Furthermore, high dimensional accuracy was no longer guaranteed due to the automation of pallet production. And it is becoming increasingly difficult to buy fixed lengths on the market,” explains Marc Rückerl, who manages the company together with his brother Roman. Thus, a new cutting solution had to be found. "We looked at various providers. We liked the quality of the Kallfass solutions right from the start,” reports Roman Rückerl.

In addition, the proximity to Kallfass in Baiersbronn-Klosterreichenbach spoke in favour of the Baden-Württemberg supplier. Moreover, communication with Kallfass project manager Matthias Link was very good right from the start, as the two confirm. Kallfass supplied Holzwerke Rückerl with a cutting and stacking system, which has been in operation since March.

Flexible system for high performance

Rückerl's typical approach is to purchase sawn timber directly from local sawmills. The new Kallfass line is designed for lengths from 2.5 to 5.1 metres. The wood dimensions for pallet production range from 17 to 22 mm thick and 75 to 150 mm wide. "We usually use the system to cut the raw materials for the Euro pallets. However, its design is very flexible and allows us to process squared timber up to 80 x 80 mm as well," reports Roman Rückerl. The system's target output is around 400 m³ per shift. The sawn timber is separated in layers using a tilt destacking system for double wood packages with automatic stick removal. The boards are fed onto a chain conveyor and then to the operator station using an unscrambler and an alignment roller conveyor. "We deliberately decided against a step separator here because it slows down the system,” says Marc Rückerl. Kallfass installed a thickness monitoring system immediately after the operating station. "If two boards are lying on top of each other, the system stops automatically and the employee can separate the timbers manually," explains the Kallfass project manager.

After the layers are created, the boards are cut to the finished size using the Kallfass multiple cross-cut saw. "This saw is equipped with five saw aggregates; four of which can be positioned automatically," explains Link. The next step is the stacker, which is designed for an output of at least 13 layers per minute and is equipped with ten stick magazines. What makes it unique: To facilitate internal logistics, the boards, which are cut to the exact length required, are stacked directly onto pallets. To achieve this, Kallfass implemented an automatic pallet feed from a magazine. An employee uses a forklift truck to place the required pallets on a roller conveyor. The stacks are precisely aligned and fed to the empty pallet magazine. Subsequently, the magazine feeds the hoisting unit of the stacking system with the pallets and positions them so that the boards are stacked exactly in the centre depending on the length of the parts. To ensure adequate time for collecting the wood packages, there is a generously sized buffer roller aisle at the outlet. Apart from the forklift operator, only one employee is responsible for the entire cutting process.

Flexible Sortierlösung für KMU-Sägewerk EN Flexible sorting solution for SME sawmill

With a cutting capacity of around 25,000 cubic metres per year, the Wolf sawmill is a classic small and medium-sized enterprise (SME). The company's history dates back to 1870. Today, Christian Wolf runs the firm in cooperation with his mother, Gabriele Wolf, and represents the fifth generation of the family-run company. When using a gang saw and a small profiling system, and a downstream circular edger saw, the production of solid structural timber (KVH® for short), glued-laminated timber (GLT) lamellas, packaging squared timber, side products or raw goods from sawn timber (rough planer) is relatively easy. The classification and stacking of the diverse assortments were previously carried out using a simple length sorting system. In this case, employees subsequently stacked the sawn timber manually. “It was too labour-intensive and we find it very difficult to recruit staff. In addition, this sorting has significantly limited our performance,” explains Wolf. In order to become faster and more flexible, a new solution was needed.

Perfect handling

Wolf Jr. looked at several suppliers. Ultimately, he liked the concept of Kallfass, Baiersbronn-Klosterreichenbach, Germany, the best: “Kallfass has always built very reliable sorting systems and was able to complete the project in a very short time. I particularly liked the agility in the planning – all of our requests and ideas were implemented promptly and the new sorting system is specially adapted to the size of our sawmill,” explains Wolf. The renovation work was carried out last year, and the new Kallfass sorting and stacking system has been in operation at the Wolf sawmill since March. “The entire commissioning process went absolutely smoothly. The Kallfass technicians were excellent, as were the programmers," says Wolf, full of praise for the mechanisation specialist's handling. “We now have countless possibilities to deal with our qualities and dimensions.

Kallfass supplied the complete sorting and stacking system, from the transfer downstream of the trimming and circular resaw. The latter is designed for lengths of 1 to 5.1 m and a maximum cross-section of 140 x 180 mm. A conveyor belt transports the squared timber or the main product and boards to two separate buffer decks, which are positioned directly underneath the boxes. “The buffers are dimensioned in such a way that an entire sawmill production output of three to four hours of, for example squared timber, will find space,” explains Kallfass project manager Matthias Link.

After separation, the goods go to the assessment station. The employee can set a back cut of up to 50 cm at the zero line by dragging. If a cross cut is to be made on the opposite side of the wood, the wood is marked with a luminescent chalk. The cross-cut is done later, immediately before stacking. There is also a turning device in the area of the assessment station so that even heavy pieces of wood can be qualified on all four sides. Any unsuitable pieces of wood can be separated into planks and squared timber and ejected into two stanchions immediately after cutting.

“Only one assortment goes directly into the stacking system at a time,” reports Wolf. After the cross-cut station, the remainder is fed upwards to the box sorting system via a level changer. After several discussions, Wolf finally decided on 30 boxes. This means that the space has been used in the best possible way. The boxes are emptied downwards onto a chain conveyor above the buffer decks. The wood then takes the same route as the unsorted goods towards the stacking system.

In order to be able to produce short lengths with millimetre precision, Kallfass installed the proven multiple cross-cut saw. The latter is equipped with four saw aggregates, three of which can be positioned automatically. In order to be able to respond to even more flexible to customer requirements, Wolf is already considering retrofitting a fifth saw aggregate. After layer creation, stacking forks transfer the lumber to the stacking system, which is equipped with four double magazines for drying and dispatch sticks. Finally, a conveyor unit supplies the sawn wood packages. While still in the planning process, Kallfass has already anticipated the possibility of conveniently retrofitting a strapping system.

In order to be able to re-sort dry packages, there is an external infeed. Here, the wood is separated layer by layer using a chain conveyor, which then transports the timber towards the assessment station. The sticks are carried via a conveyor belt into stanchions and removed.

Ein BSP-Werk für Profis EN A CLT plant for professionals

Exceptional overall concept sets new standards

Log in, finished CLT element out - and all without a forklift. This is how you could describe best wood Schneider's extremely ambitious Greenfield project in just a few words. At the newly founded site in Meßkirch, Germany, the company is implementing a trend-setting, end-to-end production line. Currently the CLT plant is being commissioned. The planned output in the sawmill is 350,000 cubic meters/year. After the final expansion, the CLT production will reach an output of 100,000 m³/year. As in the sawmill, Kallfass also plays a leading role in further processing.

Actually, best wood Schneider “only” wanted to build a cross laminated timber plant at the new Meßkirch site. “Large-format CLT was the only product that we still lacked as a complete supplier for our approximately 5,000 active timber construction customers”, reports Managing Director Ferdinand Schneider during the Holzkurier visit. In addition to solid structural timber (KVH), glulam, glued laminated timber and box girder elements, the family-owned company offers its customers numerous wood fibre insulation systems as well as comprehensive planning and consulting services.

“But then we decided to do it right from the logs and to realise a continuous line from the logs to the finished timber construction products”, says Schneider, describing the process that began seven years ago with the planning phase and continues to this day. According to Kallfass Project Manager Stefan Günther, this constant development and improvement of ongoing projects, both large and small, is characteristic of the company: “Schneider projects are organic and continue to grow. However, these further developments are always constructive, with the best solution coming out on top, regardless of who it comes from”.

The basic idea for Meßkirch was as follows: to implement a continuously automated material flow–from the log feed to the finished and glazed CLT and box elements for walls and ceilings–completely without forklift traffic and almost without manual intervention.

Well-established team

While the sawmill is already rapidly approaching full-load operation, the first expansion stage of the CLT plant is in the middle of the commissioning process. As in the sawmill, Kallfass is responsible for the majority of the mechanisation, the cross laminated timber press and numerous detailed solutions. “In addition, Kallfass, as our vendor of choice, had the planning authority”, adds Schneider, who has already successfully completed numerous projects with the Black Forest system specialists.

Conveyor belts provide the transfer between the sawmill and processing steps down the line. Subsequently, the dried and sorted goods are transported to a Microtec Optiside cup scanner, where the timber is turned to the correct side, if required. In the next processing step, the planer infeed, also from Kallfass, accelerates the goods up to 250 m/min before they are levelled and scanned, and defects are marked. The timber is then packaged in a crosswise offset, strapped if necessary, and fed on roller conveyors to a high-bay warehouse with 1,450 storage locations.

Precise production

For cross-laminated timber production, the pre-planed raw material from the high-bay warehouse is transferred to a finger-jointing line and then to a longitudinal press. Here, white glue or hot melt is used to create an assembly joint. A vacuum lifter removes the assembly joints and transfers them to another part of the Kallfass system.

Whilst the longitudinal layers are directly used to lay a dry press cake in reverse order, cross-layer segments are produced from some of the single-layer boards. “As the longitudinal layer press always produces exactly a multiple of the desired cross-layer length plus kerf, our cross-layer saw does not produce any waste”, emphasises Günther, adding that particular attention is paid to precision when formatting the individual layers and when subsequently arranging the cross-layers and laying the boards. “This means that the panel no longer has to be formatted with a saw after pressing, which saves us time and, above all, material," emphasises Schneider, who runs his panels through a sanding system, a cross-cut saw and a multi-spindle processing machine for the production of any profiles between the press and the joinery systems.

Ingenious details

When laying the dry cake in reverse order, the single-layer boards are sprayed with water on both sides for the upcoming glue application before they are placed in the actual laying station. Apart from the adhesive application system from Oest, Kallfass is also responsible for the entire plant construction, including the subsequent cross laminated timber press. The latter can hold elements measuring up to 3.6 x 16 m and a maximum thickness of 360 mm.

Once the boards have been pressed, sanded and profiled, they move on to one of Technowood's joinery lines, where Kallfass also carries out the mechanisation upstream and downstream of the machines. This includes a specially developed panel turner for CLT, which enables the elements–which may weigh several tonnes–to be turned quickly and safely.

“This means that Kallfass is responsible for the end-to-end material flow–from sorting in the sawmill to the finished panel–and I have to say that all the parts they have implemented run flawlessly”. Schneider praises the installation and the Kallfass team.

Still a lot to do

While the existing line at Schneider is designed for the production of large-format wall and ceiling elements in non-visible quality, the second line will eject elements in visible quality including glaze. Commissioning is scheduled for the coming winter. As a third expansion stage, the Managing Director mentions a production facility for hollow box and rib elements, as used in roof and ceiling constructions, which Schneider summarises under the “Box” product line. This means that the company will have numerous other essential products in its portfolio for its customers.

Schneider describes the planning and implementation of a cross-laminated timber line as extremely complex, whereby he believes there is no ideal solution: “Depending on the objectives and framework conditions, each new CLT plant is always a path of the best compromises, which we realise together with Kallfass in the best possible way”.

Erstes gemeinsames Projekt erfolgreich abgewickelt EN The first joint project has been successfully completed

“Previously, we also had to re-sort and stack the dry goods at our sorting plant. Since the demand for dry goods has risen steadily, re-sorting was only possible with considerable extra hours - sometimes the system also ran on Saturdays or we started on Sunday evening”, remembers Christian Rockel, Production Manager at Robeta Holz. This bottleneck had to be removed. Those responsible for the sawmill in Uckermark, Germany, approached Kallfass, Baiersbronn-Klosterreichenbach, Germany, with a relevant enquiry. “Kallfass has a very good name in the industry”, Rockel reasons. “We have also been approached by pallet manufacturers who said: If you cut the sawn timber with a Kallfass system, then we'll buy from you”, says the production manager and smiles. He is referring to the high accuracy of the mechanisation specialist's multiple cross-cut saw.

Complete package instead of the “basic”

“Originally, a smaller restacking system was envisaged” recalls Kallfass Project Manager Enrico Goldhahn, and continues: “However, during the discussion it turned out that Robeta wanted to be more flexible and we ultimately delivered a fully comprehensive system with some technical refinements”. Among other things, Robeta Holz also paid attention to ergonomics: All system components are easily accessible and the walkways are particularly wide. This results in the best work conditions for the employees. “We had enough space for the planning and for the system, so we optimised the process. A great reference project has been created”, Goldhahn clarifies. His colleague Matthias Link, responsible for sales at Kallfass, adds: “All the responsible people, such as electricians and locksmiths, were involved in the project right from the start. That made the coordination much easier.”

Robeta Holz built a new hall for the Kallfass system. The assembly work started on 6 September 2022. In January, the trial operation could already begin. As mentioned, the new restacking equipment is intended for dry goods. However, Robeta Holz can also use this equipment for fresh sawn timber. The system is designed for cross-sections from 16 x 75 to 125 x 200 mm with a length from 0.8 to 6.3 m.

Clean separation

The sawn timber feed offers space for several packages. “For a higher output, the system is equipped with two conveyors”, Link explains. The hydraulic tilt destacking unit has pneumatic pawls for better stick separation. “The pine is slightly tacky - with the slight push, however, the sticks detach better from the lumber layers”, Goldhahn explains. The sticks are collected separately and space-optimised in stanchions.

After separation and downstream of an alignment roller conveyor, the workpieces reach the assessment station, where an employee performs a final quality check. The subsequent Tongloader® cycles the boards and planks – regardless of the cross-section – onto the downstream chain conveyor at a rate of up to 120 cycles per minute. The Tongloader® is equipped with an anti-twist device. “This ensures that cross-sections that are approximately square are not transported on edge”, explains Goldhahn. The workpieces pass through the Brookhuis moisture measurement system in a transverse run-through. “Pieces that don't fit are ejected, as are the rejects”, Link points out during the tour. The respective boards drop down through a sorting flap onto a belt below and arrive at two points on a table where they can be removed separately.

Subsequently, the good parts move through the Kallfass multiple cross-cut saw. The latter is equipped with five saw aggregates – four of which can be positioned automatically.

Adjustable magazines

The stacker has a capacity of up to 12 layers per minute. Kallfass has further strengthened this stacker for large wood dimensions. The system has eight double magazines for stacking sticks and sticks being disposed of. “The magazines can be positioned automatically. This also allows more sticks from a magazine to be placed on the sawn timber layers if required. The motorised adjustment allows the sticks to be positioned closer to the cutting edge. The minimum distance corresponds to a stick width plus 10 mm”, Link explains and adds: “We have also equipped the existing sorting system with these new stick magazines.”

The finished packages arrive at the Kallfass automatic foiling station. “This station can also be equipped with unfolded film up to 3.6 m wide”, informs Link. The wrapped packages then enter the Fromm package press with two squared timber magazines, are strapped and transported out of the hall through a high-speed door. The parcels are transferred to the pick-up point for the stacker via an angular transfer device.

“Kallfass has done a very good job. The cooperation was impeccable – the handling of the installation was also smooth due to the good planning”, reports Rockel. “We can now respond to customer requests much faster and have brought the working hours back to a normal level. The system is operated by three employees and one forklift operator. The output of the system is very high, consequently requiring only a single-shift operation. I am happy every day about the successful project”, says the production manager, visibly satisfied.

Neue Stapellinie mit einer technischen Raffinesse EN New stacking line with technical sophistication

Holzwerke van Roje, Oberhonnefeld-Gierend, Germany, originally focused on rather small batch sizes with its sawmill and primarily serves niche markets with its products. In the past year, however, something has changed significantly: When the company's CLT plant is up and running, around 25 to 30% of the sawn timber produced in the sawmill is sent for further processing. “Many of our investments in recent years have been aimed at further increasing profitability in production. The new stacking line is also part of this”, explains Gerhard Hauschulte, Managing Director at Holzwerke van Roje and adds: “Now that we have the new stacking line, we can get more out of the side products”. When it comes to the implementation, Holzwerke van Roje relied on the expertise of Kallfass, Baiersbronn-Klosterreichenbach, Germany. “We have already worked with Kallfass many times, for example in the planing mill. We were always fully satisfied. Moreover, Kallfass offers solid mechanical engineering”, Hauschulte justifies and says with a smile: "Besides, Kallfass had a building time frame that we had to use”.

The schedule was very demanding and the machine builder completed the conversion at the turn of 2022/23: Dismantling of the existing system, installation of the new one and commissioning were completed in less than three weeks.

More yield with “Scandinavian stacking”

The new stacking line from Kallfass makes it possible to form sawn timber packages with different lengths and stack them flush right/left. In the CLT plant, the boards are placed in a finger-jointing line. This means that the length of the raw material is not important. If short boards with different lengths can be cut and stacked without a grid, which we previously had to cut back to fixed dimensions, we can significantly increase our yield”, Hauschulte informs right in advance about the advantages of the new system. “In the German-speaking countries, such packages with Scandinavian stacking have been rather uncommon so far. But we have already installed several such plants in export markets”, reports Hans Haist, Managing Director at Kallfass.

Kallfass supplied the new stacking line starting from the separation and alignment unit of the side goods downstream of the box emptying unit. The boards are first transported past the employee, who can still eject timbers that are not acceptable. A Tongloader® cycles the workpieces in the direction of the next cross conveyor at a rate of up to 80 cycles per minute. If Scandinavian packs are formed, the zero edge is shifted every second board thereafter. The system is designed for a board length of 2.5 to 6.1 m. “If we require shorter dimensions, there are end stops at 3.6 and 4.6 m when shifting the zero edge”, Hauschulte points out during the tour. "The alignment for the Scandinavian packages can be deactivated so that completely “normal” stacks can also be formed”, adds Haist.

The subsequent multiple cross-cut saw from Kallfass is equipped with two sawing aggregates for zero and end cutting. Following the layer formation and transfer, the stacking system is installed. This system outputs up to ten layers per minute and is matched to the edging system. The stacker has nine stick magazines for automatic stick placement process. For workpieces up to 6.1 m in length, all stick magazines are used to stabilise the package in the best possible way. For workpieces of shorter lengths, fewer stick magazines are used. “We haven't had any problems with stability so far”, Hauschulte confirms. "We have also already made preparations for an automatic stick placement using a robot”, Haist emphasises.

Hauschulte is very satisfied with the process and the investment decision: “We can now generate more yield and we want to continue to add value in the future”.

Anlage überzeugt in jeder Hinsicht EN The system meets all expectations

Weiss Holzwerk GmbH, a company with roots in the Bavarian town of Julbach in Germany, dates back to the 12th century. It produces a wide range of standard and custom pallets, as well as all types of wooden packaging. The raw material for this comes from the company's sawmill. “We cut around 36,000 solid cubic meters of soft wood every year. The majority of production is used for our own further processing whereas the superior quality is sold to carpenters, joiners, timber construction companies, and individuals”, according to Jürgen Martlmüller, the Managing Director. He attaches particular importance to regional marketing and the comprehensive use of wood. For example, they also take back old pallets and repair them. “Only when a repair is no longer possible are the pallets dismantled, components reused if possible. Then the leftovers are shredded and the shredded material is thermally recycled in the company's biomass heating plant in a CO2-neutral way”, Martlmüller emphasises. The machines and equipment receive the same level of care: these are carefully maintained and, if necessary, repaired, upgraded and overhauled by our staff, so that you can get the most out of the equipment's useful life.

Multiple reasons - for investment and equipment supplier

However, this was no longer possible with the previous restacking line: “These systems had definitely reached the end of their service life”, says Martlmüller, thus stating the first reason why he decided to make the investment. To guarantee our pallet customers a 24 hour delivery window, we are equipped with a backup system for nearly every line—from a standby gen set to a second pallet line. As we have discontinued the use of our old cross-cut saw, we have had to introduce a new system that accurately stacks and cross-cuts the sawn goods for our pallet production”, is the second rationale. Thirdly: The stacking feature allows the wood packages produced in the new system to be directly loaded into the drying chamber. This was not a viable option in the past.

Thus, Martlmüller made a decision in favour of a restacking unit from the Kallfass location in Baiersbronn-Klosterreichenbach, Germany. “After reviewing multiple suppliers, Kallfass’ system excelled in many ways”, says the Managing Director. The system manufacturer provided the best concept in terms of technology, economy, and price. Additionally, Kallfass is renowned in the industry for its excellent designs and its robust products. The initial commissioning of the new restacking system took place in March 2022. This past January, the Kallfass increased the size of their systems with the addition of a buffer chain conveyor and a step feeder. “After the first few months it became apparent that feeding bundles is the rule rather than the exception. For this reason, we have again upgraded these systems”, explains Matthias Link, responsible Sales Manager at Kallfass.

Restacking wood packages or bundles

The Kallfass restacking system starts with a package chain conveyor or the downstream tilt destacking for wood packages and bundles. The stacking sticks fall automatically onto a conveyor belt and are collected. The boards—measuring up to 5 m long—first slide onto a buffer chain conveyor and then enter into the step feeder. “In these systems, both steps move so that the load is divided. This ensures a reduced energy consumption”, Link explains. The boards fall into the unscrambler’s trough, are subsequently right-aligned and transported to the accumulation chain conveyor. Here, an employee checks the timber and sorts out any unacceptable goods. This is followed by the layer-by-layer charging of the Kallfass multiple cross-cut saw. This saw is equipped with seven sawing units, six of which are completed automated and can be positioned as required. According to Kallfass, the shortest cutting length is approx. 760 mm. A waste conveyor is used to remove the scrap wood. Utilising placement forks, the board layers that were cut exactly to size are transferred to the stacker. This stacker has a unique feature: In order to facilitate further internal package manipulation, the boards are stacked on a pallet. To do this, the operator places the pallets in stacks onto a roller conveyor that has space for three wood packages. “First, the stacks are precisely aligned and then fed to the empty pallet magazine. Which feeds the hoisting unit with the pallets”, Link explains during our tour. Only when all the pallets are positioned can the hoisting unit move upward and begin the stacking process. The stacking system is equipped with board magazines. “Currently, Weiss Holzwerk only uses boards as intermediate sticks. In the future, sticks with a cross-section of 40 by 18 mm or 48 by 18 mm can also be used”, informs Link.

Martlmüller is enthusiastic about working as a team with Kallfass: “It was always a cooperation built on fairness”, confirms the Managing Director. “The employees, whom we involved in the project from the very beginning, are also happy with the new system.”

Das voll automatisierte Sägewerk EN The fully automated sawmill

“We were seeking partners who would join us in planning an unusual sawmill with us. In Kallfass we found that partner, who also has the necessary open mind to think about matters in a new and alternative way. In addition, we already knew Kallfass who had successfully completed projects in our main factory in Eberhardzell, Germany. So it was easy for us to decide to collaborate again on this major project”, says Andreas Schilling, site manager at best wood Schneider in Messkirch, Germany, describing the excellent cooperation with Kallfass.

The scope of delivery of the mechanical engineering firm from the Black Forest starts at the takeover of the timber directly downstream of the two sawing lines. Whilst using two log band saws and a chipper-canter line for all logs with a crown diameter of less than 30 cm, Schneider GmbH will be cutting approx. 350,000 solid m3/year once the production has reached its full expansion stage. “By combining band and circular saw technology, we are particularly flexibly positioned and can act as a full buyer for the forestry sector. In times when procurement situations become increasingly problematic, this is particularly important”, reports Schilling.

Flexible sorting

Four buffer levels, one level directly above the other, take over the sawn timber. “Each level is designed for the exact filling quantity of the subsequent drying package. This enables us to time the wet sorting process selectively”, explains Managing Director Hans Haist of Kallfass. The entire sorting system can process boards measuring 3,600 to 4,300 mm long and 95 to 259 mm wide. Thicknesses from 36 to 53 mm can also be processed, ensuring the greatest possible flexibility for further processing in the company’s sorting area. In terms of efficiency, the system also meets all requirements. It operates at 80 cycles per minute in both wet and dry areas.

28 m³ of sawn timber per dry wood package

During the process, the individual levels are emptied one by one. Subsequently, the boards are separated before their thickness is measured, and the Kallfass’ multiple circular cross-cut saw trims the excess length of the lumber as required.

The wood packages are then automatically stacked for drying purposes. best wood Schneider GmbH works with mixed widths and thicknesses. “This makes little difference for the continuous kiln, and the Kallfass systems also cope very well with it”, Schilling informs us.

Many companies already rely on a drying chamber solution; therefore, mixed packages are nothing unusual in the timber world. When you walk through the factory, what immediately strikes you is the size of the individual packages of sawn timber. “The wood packages measure 2 m wide by 4 m long. The most impressive aspect, however, is the height of these packages, each one standing 6 m tall. That means, depending on the moisture content of the lumber, up to 30 tonnes are transported through the halls with each package. The demands on our automation systems were, therefore, exceptionally high”, explains Haist.

Fully automated transport

Subsequently, the finished stacked wood packages are hydraulically lowered and automatically taken over by the dryer infeed. “The complete material flow is 100 % automated. This means zero forklift operations and zero manual transport whatsoever between the individual production phases”, says Schilling enthusiastically about the concept and the mechanical implementation provided by Kallfass. A total of 150 transport trolleys are in circulation simultaneously, ensuring a constant flow of material throughout the entire production system. “The fully automatic charging of the continuous kiln on rails is something unique and certainly one of a kind, at least in Central Europe,” Haist comments on the operator-free material transport.

Sorting system with bypass

Once the wood packages are ready and dried, Kallfass takes over again and uses a vacuum lifter to destack the packages. Next, a brush automatically sweeps and tosses the stacking sticks onto a conveyor belt. The latter moves the stacking sticks along the dry sorting unit back to the wet sorting area. Here, before the sticks are used again, they are measured and checked for their ongoing suitability using a board shape scanner.

The dried slats are then separated again, and their dimensions are measured using a laser before the wood moisture content is measured without contact in a continuous process. The downstream multi-level sorting system extends over a length of 128 m, has 35 levels and—like the wet line—has a capacity of 80 cycles per minute. The uppermost level is about 20 m above the factory floor. “Our unsorted cutting method places increased demands on the sorting process, which Kallfass addressed and was also able to comply with”, explains Schilling.

An absolute Kallfass unique feature is the integrated bypass system, which connects the dry with the wet sorting line. If a slat does not pass the moisture test, it is immediately fed back to the wet sorting line and thus reintroduced into the process.

Connection to CLT plant

The Microtec Optiside cup scanner detects each dried and sorted slat leaving the sorting system. Subsequently, the Kallfass planing machine infeed is accelerated by the up to 250 m/min. Downstream of the pre-planing machine, a Microtec Goldeneye scanner optimises each slat for subsequent cross-cut processing. Finally, the slats are packaged again using a cross-stack method and transported directly to the future CLT plant, or strapped and temporarily stored using a hoisting unit to load the lorry.

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

The distinctive feature of the planing line and quality sorting line starts with the package feed. In order to achieve this, Kallfass used a two-level design. “At the lower level, the packages are transported in a straight line, moving towards the laminated timber production system. A long roller conveyor moves the wood from the upper level to the tilt destacker”, explains Enrico Goldhahn, Kallfass’ Project Manager. The packages are separated in layers, and the stacking strips are automatically collected. During the transport, the boards are guided to a pre-separator which then passes the boards on to the unscrambler. A thickness measurement device is integrated into the latter. If two pieces of wood are placed on top of each other, both pieces are ejected and returned to the unscrambling trough. The aim is to keep all manual operations as low as possible. After alignment at the zero line, a TongLoader® unit separates the board film. Goldhahn puts the TongLoader’s® output at a maximum of 80 boards per minute.

All measurements are taken during the transverse run-through

While the lumber follows the transverse run-through, it also passes the Mesutronic metal detector and a face cutter, which prepares the lumber for the subsequent strength measurement process. Microtec also supplied the M3 Scan moisture meter, the Optiside cup scanner and annual ring detection system, the Curvescan 3D board shape scanner, and the Viscan strength grader. All measurements take place during the run-through process. The Optiside scanner transmits a signal to the downstream Kallfass turning device, prompting it to rotate the lumber. Workpieces that do not meet the specified criteria are rejected.

Planing or quality sorting

At this point, the paths diverge: If a pure quality sorting operation is selected, a bypass is used to convey the good lumber past and beyond the REX planing machine at a speed of up to 400 m/min.
Variant 2: The good parts requiring planing are fed into the Kallfass planing machine, where an acceleration conveyor optimises the infeed of the timber. Goldhahn indicates that the intake system can reach up to 80 cycles per minute. The feed speed of the planing system can reach up to 350 m/min. Behind the planer, a conveyor belt advances the boards to the Microtec Goldeneye. The entire intake, scanning, and outfeed areas can be shifted to the left out of the planing line or to the right into the bypass line. If scanning is not selected, a motor pushes a bypass belt into the line instead of the scanner. After scanning, the parts move into the marking station, which can also be pushed into the line. Slowdown belts transfer the parts to the roof-top chain conveyor. “Here, the parts can come either from the bypass or the planing line – never from both lines at the same time”, Goldhahn explains.

At the sorting station, an operator arranges the boards according to three quality levels. He advances the pieces manually—one piece at a time—onto the assessment chain conveyor. A ram infeed unit transfers the goods (80 pieces per minute) to the infeed conveyor of the level sorting unit. In this area, the widths and thickness are measured. In addition, three Lumi scanners read the applied marking and the control system compares the marking with the scan result. After that, they part ways again.

Bundling systems at a height of 6 m above the level sorter

Only workpieces that have been split in the planing machine and are narrower than 70 mm, as well as profiled boards, enter the Kallfass bundling system. The latter is installed 6 m above the level sorting unit. The sticks are labelled on an ascending belt conveyor before an aligning roller conveyor adjusts the sticks at the zero line. A motor-driven, height-adjustable gantry for applying labels is fitted with two labelling devices. Kallfass automatically assembles the sticks into bundles and straps them together. “We delivered six bundling units—so there is less adjusting required”, explains Goldhahn. Another labelling unit for the finished bundles is installed in the outfeed area.

All other boards enter one of Kallfass' six sorting levels. “Depending on the dimension, a package may have to be separated and placed on two levels. Because of the existing structural constraints, we had to proceed with this option”, Goldhahn explains. A pivoting conveyor is used to empty the individual levels. These boards are labelled as they pass through the production line.

Once the filling level has been reached, the levels are emptied, and the layers are formed. The boards pass through the Kallfass multiple cross-cut saw with five sawing units. The shortest cutting length is 800 mm. “The pivoting saws are equipped with tandem cylinders. This allows us to vary the cutting height up to 160 mm. In addition, the zero saw can be adjusted by 500 mm”, explains Kallfass’ project manager.

Subsequently, the stacking takes place. The machine is equipped with eight stick magazines. In order to achieve greater stability for the ongoing transport, the Kallfass system can also stack the boards diagonally. For lower packages, an auxiliary hoisting unit with swivel forks increases the capacity.

The wood packages intended for the subsequent production of glue-laminated timber are fed directly into this production area using a roller conveyor. A forklift truck can be used to remove packages halfway along the line. At the end of the roller conveyor, an automatic crane made by Voith automatically removes the packages. Shipping packages are moved to the right-hand side and below the stacker. Here, a height-adjustable film dispenser automatically places the film on the stack first. The Kallfass mechanical system transfers the stack to the strapping unit, which includes a packaging press and applies four edge protectors to the stack. Squared timbers are then placed on the package. The roller conveyor is partitioned into three sections so that strapping and placing the squared timber can take place simultaneously. Finally, the wood packages can be stacked by the downstream stacker. “As an alternative to foil wrapping or strapping, there is a bypass that is integrated inside a foiling tunnel. In order to use this option, the packages are deflected to the left-hand side downstream of the stacker”, explains Goldhahn.

This is the third installation

Kallfass already delivered a smaller planing line for Cordes in 2018, which was completely rebuilt in 2020 and upgraded in order to include a bundling system. The assembly of the large-scale project described here started in 2021. Since 2022, the processes have been gradually improved and optimised. “We delivered approximately 65 lorries containing system components to Bremerhaven in order to construct the new quality-sorting and planing facility”, says Goldhahn, describing the overall scale of the project. The system can process lengths ranging from 2 to 6.2 m, widths of 75 to 310 mm and 16 to 125 mm thicknesses.

Extensive planning

Good co-operation: Kallfass programmer Holger Seidt with the two Dold Holzwerke managing directors Nikolaus Faller and Matthias Huber (from left)

“Kallfass has literally given us the perfect solution in the new planing mill”.

One type of wood - many possibilities

Separation after tilt destacking: the planing machine continues to the left at the bottom, the bypass for the twin band saw at the top

Planing or restacking

Tried and tested in practice many times over: Kallfass installed the multiple cross-cut saw for the clean and separating cut

Bundling system provided by Kallfass: On the right, the flexible “mini-packaging” of the slats, on the left, the strapping station

View of the two packaging systems: Dold decided in favour of a separate system for B-goods (left in the picture)

Customised solution: Kallfass lifts the stacks of sawn timber so that the employees can attach the film and parcel labels more easily

Significantly higher performance, even with beech cuttings

Bavarian success story

Partner for decades: Ottmar (right) and Marco Bössl (left) together with Kallfass Managing Director Hans Haist (centre) in front of a stack of special pallets for the US market

There was no question about the choice of supplier

“Kallfass is virtually without alternative for cutting systems in the high-quality segment”.

Precise cross-cutting: Five saw aggregates in the multiple cross-cut saw ensure precise board cutting of softwoods and hardwoods

Precision in a confined space

For timber lengths of up to 3 metres: The parcel pick-up station is located in front of the hall entrance. The chains of the parcel conveyor are designed to be movable

Project according to plan

Automation: Manual steps are no longer necessary when placing the stacking sticks or

when feeding empty pallets

Yield and throughput increased: The new cutting system from Kallfass puts Bössl pallets back on a sustainable footing for the future

Bottleneck eliminated

Roman and Marc Rückerl with Kallfass project manager Matthias Link (from left)

Flexible system for high performance

Tilt destacking: The boards are destacked in layers and the stacking sticks are automatically separated and transported away

For a precise cut: Kallfass installed the multiple cross-cut saw with five saw aggregates

Automatic pallet feed: The cut boards are automatically stacked on pallets

Holzwerke Rückerl manufactures around 2 million EPAL pallets per year - plus special pallets

The sawn timber stacks are transported to the new Joutech system for pallet production

Finally, the stacks of sawn timber are prepared for removal on a generously dimensioned roller conveyor

Existing space used as best as possible

Perfect handling

Trusted in Kallfass’s expertise: Christian Wolf (left) with Kallfass project manager Matthias Link

”Kallfass delivered a system that was perfectly tailored to our needs.”

Separation of the boards and squared timbers towards the assessment station

The employee examines the cut material and can determine a cross-cut by pulling it

Kallfass also carried out an external infeed for dry wood packages

The proven multiple cross-cut saw from Kallfass cuts the wood with millimetre precision

Investment has paid off

Feeding to the upper floor to the 30 boxes

The finished wood packages are placed on a roller conveyor – there is also space for a strapping machine

Exceptional overall concept sets new standards

The dried raw material is transported from the sawmill ...

directly to the next hall, using conveyor belts.

There, the timber is assessed, stacked and temporarily stored in a high-bay warehouse. From there it continues to the BSP line or onto the lorry.

Well-established team

Precise production

In the cross-layer production process, the single-layer panels are cut to length using high precision and joined together to form cross-layers.

Ingenious details

Managing Director Ferdinand Schneider (right) together with Kallfass Project Manager Stefan Günther.

Still a lot to do

In the cross-layer production process, the single-layer panels are cut to length using high precision and joined together to form cross-layers.

The cross laminated timber press is just one of many components that Kallfass implemented in best wood Schneider's new CLT plant.

The finished pressed CLT panels are fed to the downstream sanding machine via a travelling roller conveyor.

New restacking system eliminates bottleneck

Robeta Wood Production Manager Christian Rockel with Enrico Goldhahn, Matthias Link and Rick Stille from Kallfass (from left)

Complete package instead of the “basic”

During the tilt destacking process, the layers are briefly held back (see arrows), so that the stacking sticks underneath are separated much easier and slide off.

Clean separation

Like a mini sorting system: The sticks in the tilt destacking unit are removed, separated and collected in stanchions in a space-optimised manner.

Adjustable magazines

The stacking unit is equipped with eight double magazines - these can be moved and positioned exactly at the cutting edge.

"I am happy every day about the successful project"

After the lumber has been separated, an employee can inspect the timber manually.

After the Tongloader® and the layer formation, the sawn timber reaches the multiple cross-cut saw from Kallfass which consists of five saw aggregates.

Kallfass also supplied Robeta Holz with the foiling station, followed by the package press and the transport of the finished packages.

The previous stacking system at Holzwerke van Roje was already approaching the end of its useful life. For this reason, the decision was made to rebuild, which was primarily aimed at increasing efficiency in the new CLT plant, explains Gerhard Hauschulte, Managing Director at van Roje.

Holzwerke van Roje Managing Director Gerhard Hauschulte and Kallfass Managing Director Hans Haist (left to right) in front of the new stacking line.

More yield with “Scandinavian stacking”

Kallfass delivered a new stacking line to Holzwerke van Roje at the turn of the year 2022/23.

After emptying the boxes and unscrambling the workpieces, the Tongloader® cycles the boards in the direction of the multiple cross-cut saw.

This is followed by another Kallfass innovation: the shift of the zero line for Scandinavian packages.

The Kallfass stacking system enables the formation of Scandinavian packages – the different lengths allow the yield in the CLT plant to be increased.

The multiple cross-cut saw at Holzwerke van Roje and supplied by Kallfass is equipped with a total of two saw aggregates.

During stacking, the stacking sticks are placed automatically - nine stick magazines are in use.

Jürgen Martlmüller, the Managing Director, had several incentives for investing in a new restacking line, as well as his decision to opt for Kallfass as the supplier.

In front of the stacker: Managing Director Jürgen Martlmüller at Weiss Holzwerk GmbH and Matthias Link, Sales Manager at Kallfass (from left).

Multiple reasons - for investment and equipment supplier

In an “orderly” fashion: Tilt destacking of the sawn timber packages, the stacking strips are disposed of automatically.