Schmuckstück:
Neues Schwachholzsägewerk EN
An Absolute Jewel:
New Thinnings 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 DBH lamellas, is intended for the supply of laminated wood plants. Side boards which cannot be processed are supplied to packaging customers. “The sawmill will reduce purchasing considerably for both companies in future. 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.

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

Clean sorting and packetising

Main and side boards from the HewSaw line are conveyed in two decks to the sorting and stacking system from Kallfass in Baiersbronn-Klosterreichenbach/DE. The mechanisation specialist also installed an automated stick feeder. The main and side boards are fed through a separator 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 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 fresh 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 chop saws. Placement forks then transfer the completed layers to the packet assembly system. Stacking output is up to twelve layers per minute.

The Kallfass packet assembly 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. Fresh 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, a fixture collects the sticks, bundling ten sticks together in each case. Dispatch sticks are provided using a manually charged pouch 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.

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

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

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

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

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

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

Images and text: Martina Nöstler, Holzkurier 11/2021

Sortieren EN Sorting

Automation solution
Sorting

We develop efficient sorting solutions for classified timber suitable for every size of company. Integrated sorting control system provides information on filling levels, availability and dimensions at a single glance.

 

Installation example

Box sorter with inclined boxes

Interactive installation example

  • Vereinzeln EN Unscrambling
    Controlled and gentle with material

    Controlled timber sorting

    UNSCRAMBLING WITH AND WITHOUT SINGLE FEED UNIT

    Immediately after a sawing line or tilt destacking, it is often necessary, to separate the workpieces that arrive in a batch in order to form a material film/carpet from which they are then transferred individually or in layers to the next processing step. Depending on the required number of pieces and the material cross-sections, different technologies are used for separation or layer formation.

    Vereinzeln
  • Beschicken EN Feeding
    Continuity at high speed

    Classified according to quality

    FEEDING: Sorters

    Before timber box or level sorters can be added, single item or mixed classification must first be realised according to dimensions and quality. This is aided by warping meters, moisture analysers and wane and quality scanners. Individually assessed sticks or boards are then conveyed on for sorting using a single feed unit or rejected.

  • Sortieren EN Sorting
    Efficient and flexible

    Filling at a high cycle rate

    INCLINED BOX SORTER

    Inclined box sorters are generally used in high-performance productions, as they can be filled at a high cycle rate of up to 160 pieces/min. They ensure reliable emptying of material and are therefore particularly recommended for sorting main boards with large material dimensions.

    Boxensortierung, Sortierung_Schraegboxen

    Sorting with a restricted space requirement

    VERTICAL BOX SORTER

    Use of a vertical box sorter can be sensible in confined space conditions, as vertical boxes need less space than inclined boxes and can accommodate more product boxes in the same area. Vertical boxes are mainly used for sorting side boards, as the box geometry makes emptying difficult and is not suitable for large material dimensions. The emptying direction can be suitably adapted to optimise the material flow. Vertical boxes are filled at a cycle rate of 120 pieces/min.

    Boxensortiernung, Sortierung_Senkrechtboxen

    Timber product assortment

    IDEAL VOLUME

    The number of timber products determines the number of boxes. A box should ideally correspond to the volume of a stacked package, with the height of the boxes corresponding to the package cross section.

  • Stapeln mit Umreifen EN Stacking with strapping
    Time-saving process solutions

    Fully automatic material flow

    STACKING: Shipping packages

    Stacking of timber (including in multiple lengths) can be realised with stacking tongues or vacuum lifters, with the timber being collected in layers and deposited layer by layer on the shipping package to be formed. Shipping strips can be laid between several layers to stabilise the shipping package. Strip laying is automatic. Where necessary, the shipping package is stabilised additionally through final strapping. Squared timbers can be optionally included on the package underside, and the packages can be pressed hydraulically together if desired. Customers who do not wish to have stabilising strips (e.g. because the package only needs to be transported within the company) may avail of offset stacking.

    Stapeln-Versandpaket

    Effective air circulation, thanks to dry sticks

    STACKING: Drying packages

    Wooden sticks are laid between each layer when stacking timber that is still damp in drying packages. The intermediate sticks ensure adequate air circulation during drying and accelerate the drying process. The drying sticks are laid by stick magazines.
    Option: Workpieces of different widths can also be stacked with spacing with the aid of a servo slide.

    Stapeln-Trocknung
  • Optional equipment

    The added bonus for your success! This equipment allows you to enhance your product quality while simultaneously reducing changeover times and personnel costs.

  • Eintakter EN Single feed unit

    Reliable conveyor transfer

    SINGLE FEED UNIT

    The quality of individual boards cannot be assessed or measured without precise cycling in. Both the desired production speed and the homogeneity of the timber determine the cycling in process in this respect. With a consistent board thickness and production speed of maximum 80 cycles/min, individual boards are backed up and, using retaining pawls in combination with a plunger and acceleration conveyor, transferred individually to the next conveyor.

    Eintakter
    Eintakter_TongLoader
  • Waldkantenscanner EN Wane scanner

    Efficient process sequence

    WANE SCANNER

    Qualitaetsscanner
  • Installation example

    Multi-level sorter with film layers

    Interactive installation example

    Solutions from a one-stop provider

  • Zuführen & Entstapeln EN Charging & Destacking
    Separation of single and multiple packages

    High performance and a high cycle rate

    TILT DESTACKING

    For separating single and multiple packages with and without intermediate sticks upstream of planing and sorting systems. The packages are received in a transverse direction by a lifting unit, pivoted through approx. 45° and conveyed on to the skid edge. Layer by layer, the timber pieces now slid over a skid edge (which can be flexibly adjusted) to even out distortions in the layer.

    Entstapeln_Kippenstapelung

    Minimising setup times

    TILT DESTACKING OF DOUBLE PACKAGES

    Tilt destacking of double packages can halve setup times, minimising production costs as a result. The intermediate strips in double packages can be removed with the aid of a stick stripper (optional) and collected and sorted for further use or disposal.

    Entstapeln_Kippentstapelung_Mehrfachpakete

    Careful and gentle at a medium cycle rate

    VACUUM DESTACKING

    VVacuum suckers lift the topmost layer of a package and deposit it gently in a transverse direction on the conveyor. This careful handling is particularly suitable for avoiding surface damage to planed workpieces. The vacuum destacker is suitable for production lines with short to medium cycle rates.

    Entstapeln_Vakuum

    Longitudinally and transversely at a low cycle rate

    PUSH-OFF DESTACKING

    This destacking involves pushing the uppermost layer of a package to the downstream process. Pushing can occur in a transverse or longitudinal direction, depending on the space requirement. This destacker is used on production lines with a low cycle rate.

    Entstapeln_Kippentstapelung_Abschiebeentstapelung
  • Beschicken EN Feeding
    Continuity at high speed

    Continuous material supply

    FEEDING: Planing machines

    Whether in layers or destacked, transverse or longitudinal, a continuous supply of timber is vital when feeding machining processes such as planing or sawing. Accelerating rollers ensure high feed speeds. The use of a slow-down belt is necessary as of a speed of 150m/min to decelerate the pieces after planing.

    Beschicken-Hobeln
  • Beschicken EN Feeding
    Continuity at high speed

    Classified according to quality

    FEEDING: Sorters

    Before timber box or level sorters can be added, single item or mixed classification must first be realised according to dimensions and quality. This is aided by warping meters, moisture analysers and wane and quality scanners. Individually assessed sticks or boards are then conveyed on for sorting using a single feed unit or rejected.

  • Sortieren EN Sorting
    Maximum wood protection

    Careful material handling and space saving

    BUFFER LEVEL SORTER

    Use of a buffer level sorter always makes sense where timber should be sorted with as much care as possible, but the sorter should not require excessive space. Nevertheless, the space required by a buffer level sorter is greater than that for a box sorter, as an emptying section must be provided after each level. As the timbers in the levels lie loosely on top of each other and need to be separated prior to filling and after emptying, this sorter is only conditionally suitable for planed workpieces.

    Sortierung_Pufferetage

    Ideal for planed workpieces

    FILM LAYER SORTER

    A film layer sorter takes up a lot of space, as the levels are arranged one above the other. However, it is ideal for careful sorting of classified planed timbers, as each board film lies individually in the levels and need not be separated again after emptying. This enables subsequent stacking of the layers and a maximum stacking capacity.

    Sortierung_Filmetage

    Timber product assortment

    IDEAL LAYER LENGTH

    The number of assorted products determines the number of levels, and the required length of a level is determined by the cross-sectional size of a package. Filling and emptying of the levels occurs fully automatically in each case.

  • Beschicken EN Feeding
    Continuity at high speed

    High throughput

    FEEDING: Multiple cross-cut saws

    Workpieces can either be fed individually to the multiple cross-cut saw with the aid of a single feed unit or in entire layers, ensuring a constant material flow at even a high production speed.

    Beschicken_Mehrfachablaengsaege
  • Mehrfachablängen EN Multiple cross cutting

    Flexible and efficient

    The ends of raw or planed timber workpieces are cut with millimetre accuracy to the desired fixed lengths in cross-cut saws. The workpieces can be processed individually or layer by layer. Powerful saw motors and feed speeds of max. 50 m/min ensure a high throughput.

    Several cutting programs can be stored to ensure maximum production flexibility, or data can even be imported from ERP systems and master computers.

    Ablaengsaegen_Mehrfachablaengen
  • Stapeln mit Umreifen EN Stacking with strapping
    Time-saving process solutions

    Fully automatic material flow

    STACKING: Shipping packages

    Stacking of timber (including in multiple lengths) can be realised with stacking tongues or vacuum lifters, with the timber being collected in layers and deposited layer by layer on the shipping package to be formed. Shipping strips can be laid between several layers to stabilise the shipping package. Strip laying is automatic. Where necessary, the shipping package is stabilised additionally through final strapping. Squared timbers can be optionally included on the package underside, and the packages can be pressed hydraulically together if desired. Customers who do not wish to have stabilising strips (e.g. because the package only needs to be transported within the company) may avail of offset stacking.

    Stapeln-Versandpaket

    Effective air circulation, thanks to dry sticks

    STACKING: Drying packages

    Wooden sticks are laid between each layer when stacking timber that is still damp in drying packages. The intermediate sticks ensure adequate air circulation during drying and accelerate the drying process. The drying sticks are laid by stick magazines.
    Option: Workpieces of different widths can also be stacked with spacing with the aid of a servo slide.

    Stapeln-Trocknung
  • Optional equipment

    The added bonus for your success! This equipment allows you to enhance your product quality while simultaneously reducing changeover times and personnel costs.

  • Qualitätsscanner EN Quality scanner

    Best timber

    QUALITY SCANNER

    Qualitaetsscanner
  • Beschicken_Mehrfachablaengsaege

    Sägen EN Sawing

    Automation solution
    Sawing

    Our CNC-controlled multiple cross-cut saws are an integrated component of automated production lines. There is a permanent focus on a continuous material flow and the efficiency of the process during linkage of individual processes.

    Installation example

    Multiple cutting of timber

    Interactive installation example

    Solutions from a one-stop provider

  • Vereinzeln EN Unscrambling
    Controlled and gentle with material

    Controlled timber sorting

    UNSCRAMBLING WITH AND WITHOUT SINGLE FEED UNIT

    Immediately after a sawing line or tilt destacking, it is often necessary, to separate the workpieces that arrive in a batch in order to form a material film/carpet from which they are then transferred individually or in layers to the next processing step. Depending on the required number of pieces and the material cross-sections, different technologies are used for separation or layer formation.

    Vereinzeln
  • Beschicken EN Feeding
    Continuity at high speed

    High throughput

    FEEDING: Multiple cross-cut saws

    Workpieces can either be fed individually to the multiple cross-cut saw with the aid of a single feed unit or in entire layers, ensuring a constant material flow at even a high production speed.

    Beschicken_Mehrfachablaengsaege
  • Mehrfachablängen EN Multiple cross cutting

    Flexible and efficient

    The ends of raw or planed timber workpieces are cut with millimetre accuracy to the desired fixed lengths in cross-cut saws. The workpieces can be processed individually or layer by layer. Powerful saw motors and feed speeds of max. 50 m/min ensure a high throughput.

    Several cutting programs can be stored to ensure maximum production flexibility, or data can even be imported from ERP systems and master computers.

    Ablaengsaegen_Mehrfachablaengen
  • Stapeln mit Umreifen EN Stacking with strapping
    Time-saving process solutions

    Fully automatic material flow

    STACKING: Shipping packages

    Stacking of timber (including in multiple lengths) can be realised with stacking tongues or vacuum lifters, with the timber being collected in layers and deposited layer by layer on the shipping package to be formed. Shipping strips can be laid between several layers to stabilise the shipping package. Strip laying is automatic. Where necessary, the shipping package is stabilised additionally through final strapping. Squared timbers can be optionally included on the package underside, and the packages can be pressed hydraulically together if desired. Customers who do not wish to have stabilising strips (e.g. because the package only needs to be transported within the company) may avail of offset stacking.

    Stapeln-Versandpaket

    Effective air circulation, thanks to dry sticks

    STACKING: Drying packages

    Wooden sticks are laid between each layer when stacking timber that is still damp in drying packages. The intermediate sticks ensure adequate air circulation during drying and accelerate the drying process. The drying sticks are laid by stick magazines.
    Option: Workpieces of different widths can also be stacked with spacing with the aid of a servo slide.

    Stapeln-Trocknung
  • Optional equipment

    The added bonus for your success! This equipment allows you to enhance your product quality while simultaneously reducing changeover times and personnel costs.

  • Kettenoberdruck EN Top chain pressure unit

    Greater process reliability

    Top chain pressure unit

    Saw units of cross-cut saws can be optionally equipped with a top chain pressure unit that ensures greater process reliability in the event of warped timber. The saw unit and conveyor chains are synchronised to run together and pull the workpieces continuously towards the cutting blade. The chains are sheathed in rubber to avoid surface damage to planed workpieces.

    Mehrfachablängsäge_Kettenoberdruck_Ausschnitt
  • Gehrungsschnitt EN Mitre cut

    Two in one – mitre cutting

    Mitre cut

    If workpieces should be mitred, this can be achieved in a single process step with the multiple circular cross-cut saw – mitre cutting, so to speak. The saw units are equipped with an additional saw blade setting for this purpose that permits mitre cutting at different cutting angles up to a maximum of 30°. The maximum cutting height at this inclination is 100 mm, and the minimum cutting length 800 mm.

    Mehrfachablängsäge_Gehrungsschnitt_Ausschnitt
  • Leistenlegung EN Stick placement

    Automatic positioning

    STICK/BOARD MAGAZINES

    During stacking, wood packages need to be dried or stabilised for shipping with intermediate sticks. Magazine are filled either manually or automatically with sticks or boards by robots for this purpose. Dual magazines can be fitted for a second stick size. Automatic stick placement is monitored by placement grippers.

    Leistenmagazin

    Fully automatic stick handling

    MAGAZINE FILLING WITH ROBOTS

    Patented system!
    Time-consuming filling of stick magazines in this variant is realised by a robot in a patented process that carries out charging at a constant cycle rate and almost without personnel. A stick scanner can be optionally used prior to magazine filling that assesses the quality of the sticks. Only suitable sticks are subsequently separated, packetised and then prepared for robot filling.

    Roboter_Leistenlegung