Importance of capital cost reduction of chippers and their required productivity

The productivity and chipping cost of a low-investment small mobile chipper were investigated. The effect of capital cost on chipping cost reduction was analyzed by changing the service life of the chipper when assuming a target operational chipping cost set at 250 yen m^?3. Productivity of the investigated chipper was found to be at 23.7 m³ h^?1 in chip volume with fuel consumption at 14.6 L h^?1. The results showed that the chipping cost of the investigated chipper was lower than that of a higher priced and more productive grinder. Neither chipper nor grinder, however, could achieve the assumed target cost of 250 yen m^?3 even if their service lives were extended. It was necessary to withstand the initial grapple loader and the labor costs or raise the grinder’s productivity to 33 m³ h^?1 in order to reach a comparable operational cost target with that of the investigated chipper. Similarly, the grinder would have to reduce its capital cost and fuel consumption to maintain the chipping cost of 250 yen m^?3 ifproductivity could not be improved. Net chipping cost of the investigated chipper was relatively small compared to that of the tub grinder, especially under a shorter service lifespan. The investigation shows that it is feasible for small-scale forestry to introduce a low-investment mobile chipper because it does not require a large amount of material and has a low chipping cost. Moreover, lowering the capital cost or the price of chippers is a more realistic cost savings in the long term.     

Biomass harvesting in Eucalyptus plantations in Western Australia

Australia is at an early stage of exploring the use of forest biomass to generate energy. This study evaluated the biomass yield and the productivity rates of equipment for harvesting biomass in a poor-quality eucalypt plantation. The operation consisted of a tracked feller-buncher, grapple skidder and mobile chipper. Time study methods were used to measure the harvesting operation. A multiple regression model was constructed to predict skidding productivity. Biomass production was 63.9 t ha^?1 based on the recorded load weight of eight trucks. Delays were documented and analysed. The average delay for all equipment was about 30% of working time. The study results will help guide biomass harvesting managers to estimate productivity and cost of similar operation sites.     

Productivity and cost analysis of semi-mechanised and mechanised systems on the Viphya forest plantations in Malawi

At least 200 000 m³ of timber is harvested annually using semi-mechanised harvesting systems on the Viphya forest plantations in Malawi. Although these systems have long been used on the Viphya, no investigation on their productivity has so far been reported. Additionally, the absence of localised productivity analyses in Malawi has created a paucity of information on appropriate timber harvesting systems for production maximisation and cost minimisation. The objective of this study was to compare the production rates and operational costs of chainsaw/grapple skidder (semi-mechanised) and feller-buncher/grapple skidder (mechanised) harvesting systems in order to determine the economic feasibility of mechanised systems in the Viphya forest plantations. The study was conducted in Pinus kesiya compartments at the Kalungulu and Champhoyo forest stations of the Viphya forest plantations. A work study approach was followed to capture harvesting time and volume data for the semi-mechanised system. Secondary work study data were used to simulate productivity of the mechanised system on similar compartment conditions. A timber-harvesting costing model was used to analyse the results. The study showed that the simulated mechanised system was associated with lower operating costs and inventories with higher production rates than the semi-mechanised system. The cost marginal difference was US$0.89 m^–3. It was therefore established that migration to mechanised systems could optimise timber harvesting productivity on the Viphya in future, if optimal volumes are available to ensure the efficient application of the mechanised harvesting system.     

Machine productivity and residual harvesting residues associated with a cut-to-length harvest system in southern Tasmania

The cut-to-length method is a preferred method for harvest of pine plantations in Australia. The cut-to-length method studied in southern Tasmania consists of a feller-buncher, processor, forwarder, grapple loader and tractortrailers that were producing only pulp logs for the plantation owner Norske Skog. An elemental time study method was applied to evaluate the productivity of the machines within the flat terrain, Pinus radiata plantation. Multiple regression was used in SPSS to develop the productivity prediction models. The productivity of the feller-buncher and processor averaged 122.20 m³ per productive machine hours excluding all delays (PMH₀) and 84.32 m³ PMH₀ ^?1, respectively. The average productivity for the forwarder, grapple loader and truck were 80.90 m³ PMH₀ ^?1, 100.80 m³ PMH₀ ^?1 and 27.40 m³ PMH₀ ^?1, respectively. The average fuel consumption of the feller-buncher, forwarder and processor were also documented. The trial assessed harvest residue left on the site and found 238.7 GMt ha^?1 (31% of total biomass above the stump) was left of which 46% was stemwood. These research findings can be used for harvesting planning and improving logging efficiency.     

A Comparison of Productivity in Five Small-Scale Harvesting Systems

The use of small-scale harvesting equipment continues to grow in forestry in many regions of the world. This equipment includes various devices and methods used to harvesting that generally are smaller, less expensive and less productive than advanced forestry machines. The objective of this study is to compare the efficiency of five alternative extraction methods implemented in a harvesting unit located in a mixed beech and oak forest ecosystem in northwestern Turkey. A continuous time study was conducted during primary transport operations that included skidding with animal power, skidding with farm tractor, hauling with farm tractor, hauling with forest tractor, and extraction by skyline. Timber was skidded uphill on a skid trail, and an average skidding distance of 100 m for all haulage methods was considered. Average slope of the harvesting unit ranged from 20 to 40 %. Average productivities for respective haulage methods were 3.80, 6.25, 2.80, 5.25 and 10.09 m³/h. Significant differences were found between productivity of haulage methods using one-way analysis of variance. The extraction by skyline, skidding with farm tractor, and hauling with forest tractor were determined to be the most statistically different methods, the productivity of these methods was found significantly higher than the other methods. Skid trails are useful for shortening distances during forest operations and skidding with farm tractor is a productive method in small-scale forestry of Turkey.     

Time Consumption and Production Costs of Two Small-Scale Wood Harvesting Systems in Northern Greece

A field-based study was carried out to determine the productivity and production cost of the tree length (TL) and the wood assortment (WA) systems implemented under small-scale forestry conditions in two Scots pine stands in Northern Greece. Tree felling and processing productivity were estimated at 8.64 m³ per productive machine hour (PMH^?1) and 10.21 m³ PMH^?1, respectively. Wood felling and processing times were strongly dependent on dbh and total tree volume. However, when manual debarking was also considered the productivity rates decreased to 1.96 and 1.43 m³ PMH^?1, respectively. Skidding productivity was calculated to be 3.35 m³ PMH^?1 for TL and 7.17 m³ PMH^?1 for WA, respectively. Strong correlations have been found between the net skidding time and (a) the skidding distance and (b) the load per turn in both wood harvesting systems. Production costs varied greatly, from 19.38 € m^?3 up to 44.81 € m^?3 of roundwood depending on the harvesting system and the inclusion of debarking. The findings suggest that the WA system is more efficient in terms of productivity and production cost than TL, and that there is a substantial optimization potential. The optimization potential can be encoded in four suggestions: (a) opening up of more forest roads to reduce high skidding times, (b) replacement of manual debarking by mechanical debarking at the sawmill, (c) replacement of old pieces of equipment with newer ones and (d) training of the existing workforce.     

Performance,Capability and Costs of Small-Scale Cable Yarding Technology

The authors tested two mini-yarders, one for uphill and the other for downhill extraction. The two machines were modern commercial models, offering state-of-the-art yarding technology on a miniature scale and at a much lower cost than required for purchasing a full-size tower yarder. The two units must not be regarded as alternative, but rather as complementary, since they offer different capabilities and advantages. Both machines were tested while harvesting firewood from the thinning of young beech stands in Central Italy. The tests indicated that both units can reach a productivity between 1.5 and 2.4 m³ SMH⁻¹, including all delays, as well as set-up and dismantle time. Calculated extraction cost ranged between 24 and over 30€ m⁻³. The authors calculated a set of regression equations for estimating machine productivity as a function of the main work conditions. The performance of the studied mini-yarders does not seem much inferior to that achieved by professional light tower yarder under the same work conditions, but the lighter construction of the small-scale units may result in a lower resistance to wear and abuse. In any case, mini-yarders seem ideal for deployment under the typical conditions of small-scale forestry, offering a good solution to wood extraction on steep terrain, competitive with animal and winch logging in terms of productivity, cost and operator comfort.     

A study on the productivity and cost of cable logging in Turkey

Tower yarders have recently been introduced to forestry in Turkey. Clarification of the productivity and cost of logging using the tower yarder is often requested because the cost for machinery is a significant factor in all calculations concerning mechanized operations. Machines are often extremely expensive compared with the low cost of labor in developing regions. In this study, a new logging system using a tower yarder was compared with a conventional system using a stationary yarder in terms of productivity and cost. The research was conducted in the northeast of Turkey, in 1989 and 1992. The productivity of the tower yarder and the stationary yarder was found to be 5.655 m³/h and 5.002 m³/h, respectively. Harvesting cost was analyzed based on observed productivity. The harvesting costs of the tower yarder and the stationary yarder were found to be 47,410 TL/m³ and 17,553 TL/m³, respectively. With the tower yarder, the machine cost reached 93.1 % of the harvesting cost while the machine cost using the stationary yarder reached 71.1%. A part of this paper was orally presented at the 3rd Annual Meeting of the Japan Forest Engineering Society (1996).     

Wood Extraction with Farm Tractor and Sulky: Estimating Productivity, Cost and Energy Consumption

A winch and a sulky can transform a farm tractor into an effective small-scale logging machine, closely resembling a wheeled cable skidder. The additional cost of these implements is very small, but they offer significant benefits when extracting timber under the conditions of small-scale forestry. The authors developed a productivity model for skidding timber with wheeled farm tractors, equipped with winch and sulky. The origin data pool contained over 300 individual skidding cycles, extracted from 8 separate tests. Statistical analysis of the data allowed calculating a simple mathematical relationship for estimating skidding productivity as a function of significant work conditions, such as: piece size, winching distance, tractor power, skidding distance and crew size. This model can provide useful directions to prospective users, contributing to operation planning, costing and optimization. It can predict a large proportion of the variability in the data and was successfully validated using reserved cycle records, extracted from the same data pool and not used for model development. Depending on tractor power and piece size, the average turn volume and productivity can exceed respectively 2 m³ per cycle and 4 m³ per Scheduled Machine Hour (SMH). Top performance can reach 8 m³ SMH⁻¹, with heavy tractors and large logs.     

A Case Study on the Productivity of Forwarder Extraction in Small-Scale Southern Italian Forests

Most timber harvesting operations in the southern Mediterranean area of Italy can be considered to be in an early stage of mechanization. It is mainly based on agricultural tractors that are sometimes equipped with specific forest-related accessories such as winches, hydraulic cranes, or log grapples. In recent years, there has been an increase of specialized forestry machines working in Calabria, southern Italy, including forwarders, skidders and cable yarders. This study assesses the efficiency and costs of extraction using forwarders, as a mechanized alternative to agricultural tractors and horse logging. Time studies were conducted to quantify the productivity and operational cost of log forwarding for two John Deere forwarders in two different coniferous stands: (A) Calabrian pine and (B) silver fir. The empirical time study included 100 forwarding cycles (i.e., 50 for each site) that were broken down into four different work phase elements. Models for cycle time, total productivity and individual work phases were calculated. The average load per cycle was 11.8 m³ in stand A and 9.97 m³ in stand B and the average one-way forwarding distance was 306 m in A and 597 m in B. The average productivity per scheduled machine hour (SMH) was 14.4 m³ in A and 15.7 m³ in B, while the costs, calculated to be 3.60 €/m³ in A and 4.90 €/m³ in B, were considered lower respect traditional methods.     

Time Prediction Models and Cost Evaluation of Cut-To-Length (CTL) Harvesting Method in a Mountainous Forest

Time equations are derived for felling with chainsaw, skidding with cable wheeled skidder, loading with grapple hydraulic loader and trucking of logs within a cut-to-length harvesting method. The continuous time study method was applied to collect data for felling, skidding, loading and a transportation model. Multiple regression analysis via SPSS software was applied to develop the time models. Felling time was found to be highly dependent on diameter at breast height. Skidding distance, winching distance, slope of the trail and piece volume were significant variables for the skidding time prediction model. The loading time model was developed considering piece volume. Transportation distance and load volume were used as independent variables in modeling the transportation time. The net production of felling was estimated at 12 trees/h (56.65 m³/h). The net production rates for skidding, loading and traveling averaged 18.51, 41.90 and 3.32 m³/h respectively. The total cost of harvesting from stand to mill was estimated 19.70 €/m³. The skidding phase was the most expensive component of the cut-to-length method. The bucking and delimbing components were less costly than the other logging phases. The results of this study can be used for harvesting planning and productivity optimization.     

Performance of a small-scale chipper for professional rural contractors

The study determined the productivity, fuel consumption and product quality obtained with a new tractor OWered drum chipper, designed to reduce the gap between industrial chippers and small-scale chippers. The machine as tested with poplar logs and beech slabs, considered as representative of the raw material commonly used for ergy wood production. After accounting for accessory work and delays, productivity of green chips ranged between and 6 tons per scheduled machine hour, which was very good for a tractor-powered unit. Specific fuel consumption f oven-dry chips varied between 2.5 and 3.0 L per ton, or 0.6 L per m_3. These figures compared favourably with those btained from previous studies of both smaller and bigger chippers. Chip quality was very good. Samples contained no versize particles, qualifying for use in small-scale plants. The average size of beech chips was significantly larger than r poplar chips, possibly due to the higher strength of beech wood.     

Harvesting alternatives for mallee agroforestry plantations in Western Australia

The authors tested two harvesting systems especially designed for mallee agroforestry plantations on farmland. Both systems were based on versatile forest technology commonly used for conventional logging operations. They differed especially for the felling technology: small-scale drive-to-tree or industrial swing-to-tree equipment. Both systems were tested side-to-side on 12 experimental plots each. The resulting harvesting cost was 22 and 27 AU$ t^?1, for the industrial and the small scale system, respectively. Chipping represented between 60 and 80 % of the overall harvesting cost, and offered much room for improvement. The industrial system always offered the lowest harvesting cost, regardless of annual usage, when equipment mobilisation costs were not considered. The productivity of conventional forestry equipment was strongly dependent on belt stocking and tree size. If the diameter at ankle height dropped below 10 cm, economic viability decreased very rapidly.     

Cost-productivity analysis of South African pine sawtimber mechanised cut-to-length harvesting

The South African forestry industry is experiencing an increase in the number of fully mechanised timber-harvesting systems. Understanding the productivity of these systems, for which data is currently limited for South Africa, is an important step to maximise the utilisation of machines being used. A time study of a mechanised cut-to-length system was conducted in Pinus elliottii sawtimber plantations in the Southern Cape forestry region of South Africa. A harvester and a forwarder were studied with the intention of analysing the division of work time amongst work elements, modelling each machine’s productivity and cost, and estimate fuel consumption. For the harvester’s productivity, a multiple regression model was developed using diameter at breast height (DBH), average distance moved per work cycle and slope class as predictors (adjusted R²? = 0.80). The harvester had a mean productivity of 33.6 m³ per productive machine hour (PMH₀) under the current conditions with most of the productive time being used in the moving element. It consumed 25.5 L PMH₀ ^?1 of diesel on average. The forwarder’s fuel consumption was calculated as 16.8 L PMH₀ ^?1, while productivity was 46.8 m³ PMH₀ ^?1. The forwarder spent the longest portion of the work cycle in the loading and unloading phases. A productivity regression model was created that included load size and distance moved during the driving in the loaded phase (adjusted R?² = 0.78).     

Effects of Wheeled Cable Skidding on Residual Trees in Selective Logging in Caspian Forests

There are increasing demands on silvicultural practices to reduce the adverse impacts of harvesting. Damage to residual trees caused by ground-based skidding was assessed in stands with low [3.4 stems per hectare (sph), 14.36 m³/ha], medium (5.2 sph, 21.61 m³/ha), and high (7.1 sph, 25.95 m³/ha) harvest intensities. Skidding was conducted using a cable skidder. After the skidding operation, a field survey was conducted to collect data on all residual trees (species, dbh, height) and on tree wounds (size class, location, intensity of damage). It was hypothesized that increased harvest intensity leads to increased injury rates. The treatment with the highest harvest intensity was found to cause the highest percentage of damage and the largest stem wounds. The most common types of damage were stem wounds to the cambium layer and bark scrapes. In all three harvest intensity treatments the probability of individual tree damage decreased as skid-trail cross slope decreased and distance to skid-trail edge increased. It is concluded that harvesting intensity should be limited to 5 trees/ha during each harvesting operation to reduce extent of tree damage and thus future financial loss.     

Improvement and evaluation of the feller-buncher head

The high quality forest machines have recently become very popular in Japan. Many improvements on these machines have been made to fit the Japanese forests. This report describes the improvement and evaluation of the feller-buncher head of the prototype machine: FG-35. This head is mounted on the telescopic and knuckle-boom carrier. The prototype machine was improved to cut the trees, felled down on the ground or felled side ways by the storm as in the Kyushu district. And also the machine was improved so that it could be driven well without crashing the chainsaw-bar by the beginners. The testing operation of this machine carried out in Sumita-chou in Iwate and in Kuzu-chou in Oita. The productivity of the machine can be estimated at about 20 m³/h. The results of the improvement on the machine can be said to be good. A portion of this report was presented at the 106th Annual Meeting of the Japanese Forestry Society (1995).     

Small-Scale Timber Harvesting: Mule Logging in Hyrcanian Forest

Animal-powered logging is a labour-intensive operation. Mule logging is still performed in the Hyrcanian forest ecoregion in Iran as a small-scale harvesting method. Mule logging in Namkhaneh district of Kheyrud Forest within this ecoregion was studied to develop hauling regression models and estimate haulage costs. A continuous time study was conducted of hauling of sawn-lumber, pulpwood and fuelwood, to assess mule logging productivity and cost for sawn-lumber and pulpwood as well as fuelwood hauling. Hauling distance was found to be the most important cost factor in wood extraction by mule. The hourly production rates of hauling with mule were 0.84, 0.52 and 0.42 m³ for sawn-lumber, pulpwood and fuelwood, respectively. The cost of the mule hauling system USD 13 per productive mule hours. Hourly costs of mule hauling of sawn-lumber, pulpwood and fuelwood logging were 15.5, 25, and 30.6 USD/m³. Increasing hauling distances caused a linear increase in haulage cost. There appears to be an opportunity to reduce cost of log production by increasing scheduled work hours, wider utilization of mules and reducing labour cost.     

Excavator-based processor operator productivity and cost analysis in Zululand,South Africa

Operator impact on productivity and cost using similar processor machines was addressed in this case study. The study had two objectives: (1) determine the extent of operator productivity variation between six processor operators in a harvesting operation; and (2) determine potential cost implications associated with operator productivity variation. The study was carried out on the Zululand coastal plains near Kwambonambi. A multistem mechanised harvesting system, working in Eucalyptus grandis × camaldulensis pulpwood stands (with an average rotation length of seven years) was observed. The operators had all been operating their respective processors for 18 months; i.e. since the inception of the harvesting operation and had received similar in-house training. Time studies were carried out on the processors’ cycle times, and note taken of the respective operators working the machines during the time studies. Cycle time for each machine was measured as the time between a delimbed and debarked tree length leaving the processor head and the following tree length leaving the head. The required number of observations per processor was determined by cycle time and work element time variation. It was found that operators varied by up to 58% in terms of productivity, 24% in terms of utilisation and 70% in terms of cost. The potential difference in cost between using the cheapest operator and the most expensive operator was R9.34 m^?3, R4 438 d^?1 and R1 384 752 y^?1.     

Biomass harvesting from buffer strips in Italy: three options compared

There is an urgent need for new, mechanized systems that may restitute some profitability to buffer strip harvesting and motivate regular maintenance. An opportunity for innovation is offered by the growing success of chip-fed boilers, since the production of chips is simpler than that of logs and has a higher potential for cost reduction. Within this context, a study was conducted in Italy with the goals of: (a) designing three alternative chip harvesting methods for buffer strips, (b) field-testing the performance of each alternative, and (c) developing a model for estimating the cost of these methods under varying operational and economic conditions. The three harvesting methods reflected different mechanization levels, with escalating investment requirements. Overall, the study demonstrated that frequent maintenance of young, single row buffer strips generates profits only when thoroughly mechanized. Using a dedicated feller-buncher, a front-end loader for extraction and an industrial truck-mounted chipper brought the delivered cost below the 14 €/m³ loose chips (approximately 4 €/GJ) presently paid by the district heating stations. However, the intermediate-mechanization system showed the highest potential for improvements. The␣study generated a spreadsheet-based model for predicting the effects of varying work conditions and cost hypotheses.     

Determining the effect of tree size,bark-wood bond strength and tree form on the productivity of an excavator-based harvester in Acacia mearnsii in the KwaZulu-Natal forestry region of South Africa

The aim of this study was to determine the effect of tree size, bark-wood bond strength and tree form on the productivity of cut-to-length harvesting of Acacia mearnsii, using an excavator-based harvester with a SP Maskiner harvester head in the KwaZulu-Natal forestry region of South Africa. Tree diameter and height measurements were used to determine individual tree volumes, after which the trees were classified into different bark-wood bond strength and tree-form classes. Time studies were carried out to determine harvester productivity. The results showed that tree size plays a crucial role in the productivity of the harvester, but bark-wood bond strength and tree form also influence productivity. The harvester productivity varied from 5.5 m³ per productive machine hour (PMH) in 0.05 m³ trees to 16.9 m³ PMH^?1 in 0.25 m³ trees The bark-wood bond strength did not influence harvester productivity when handling small trees of less than 0.1 m³. In small trees, the productivity of the harvester was also not affected by different form classes, but as tree size increased, there was greater productivity variation between the different form classes.