Combined production of sawn timber and firewood billets at a birch sawmill in Finland: A simulation approach

Abstract

Growing markets for chopped firewood have created alternative uses for the by-products of sawmills. Based on empirical data and simulated results, the potential of birch (Betula pendula Roth, Betula pubescens Ehrh.) from commercial thinnings for combined industrial production of sawn timber and firewood billets was investigated. In the simulations, different sawing patterns were used for logs intended to combine production of sawn timber and billets for chopped firewood (‘sawlogs’), and for logs intended only to firewood production (‘firewood logs’). Finally, economical feasibility analysis was done concerning the differences between the sawmills’ traditional business concept and the novel concept combining sawn wood and firewood production. The bucking results for the volume yield of different timber assortments varied only slightly between the different bucking options, i.e. the combinations of timber assortments. The main differences in the volumes of timber assortments were due to the stand type where the birch trees were sampled (planted, naturally regenerated, mixed birch–spruce). In the sawing procedure, the output of sawn timber varied between 24% and 42% of the log volume in the sawlogs, depending on the log diameter class. As the volume yield of sawn timber and firewood billets was counted together in the case of sawlogs, the log consumption was c. 1.75 m³ of roundwood per 1 m³ of sawn timber and firewood billets. In the case of the firewood logs, the log consumption rate was considerably lower, only c. 1.35. The economic calculations showed that using the firewood approach in sawing may increase the net added value of products by €1.9–5.4 m^?3 of logs, depending on their diameter class. As a conclusion, parallel production of sawn timber and firewood from logs from the first and second commercial thinning of birch-dominated stands is a concept that could work as an alliance between a sawmiller and a firewood entrepreneur. The concept could be competitive compared with both traditional sawmilling and production of chopped firewood.     

Integrated production of semi-finished components in sawmills,part II: Management of internal operations

Recently, several Swedish sawmills have taken over production of components from customers in the furniture, joinery and house-manufacturing industries. The purpose of this study was to identify key factors in management of internal operations for sawmills with this strategy. A multiple case study design, based on face-to-face interviews with Swedish sawmill practitioners and on various forms of secondary data, produced comprehensive research information. Starting integrated production of components is a demanding strategy for sawmills. It requires deep knowledge about the customer and qualified skills in advanced further-processing of sawn wood. The complexity of quality management, production planning and cost calculation increases, and investments in processing equipment and customer relations reduce strategic flexibility. The diverging material flow complicates sawmills' possibilities to economize on scale, and they must instead economize on other factors, such as scope, combined operations and internal control. New tools for production follow-up and control, for production planning, for analysis of product profitability and for strategic partnership analysis are requested by practitioners. But, even if new analysis tools would facilitate better analysis and management of operations, the willingness and ability to innovate and learn among the personnel emerges as a key factor for success.     

Timber Demand and Supply in Northwest Vietnam: The Roles of Natural Forests and Planted Trees

Households and wood processing businesses in the provinces of Son La, Dien Bien and Lai Chau in the Northwest of Vietnam were surveyed to determine patterns of local wood demand and supply, changes in species utilized over time, and whether timber from planted trees might substitute for species previously harvested from local natural forests. In each province, 5–6 sawmills and 4–6 villages representing 3 main ethnic groups were selected for investigation. Managers of selected sawmills and 3–4 randomly selected households in each village were interviewed using semi-structured questionnaires. There was high and uniform household demand for fuelwood in the surveyed villages, making fuelwood the dominant use, in terms of wood volume. Use of sawn timber for furniture, home repair and construction consumed less wood but required logs of acceptable species. Sawmills surveyed were small, with input capacity ranging from <15 to 500 m³ of logs per year, suggesting a total log requirement of about 30,000 m³/year for the 192 known wood processing businesses in the three provinces. Most sawmills still used wood from natural forests, sourced locally or imported from Laos. A trend of switching from prized timber species from natural forests, now effectively unavailable, to alternatives from natural and planted forests was reported by both sawmills and households. Some planted species grown on short-medium rotations appear able to substitute for local sawn timber requirements.     

The role of the wood mechanical industry in the Swedish forest industry cluster

The forest and forest products form one of the most important basis for the transfer to a bio-based economy in Sweden. About 75% of the area covered by forest in Sweden is used industrially to produce raw material for the wood-refining industries. Every year, this cluster uses 75 million m³ of roundwood and has an export value of €12 billion. This review paper is devoted to the wood mechanical industry, i.e. the industry which turns the forest into sawn timber, packaging, construction wood, furniture and interior fittings. The sawmills consume about half of the volume of softwood which is felled, and about two-thirds of the sawn timber go to export without any further refining within the country. Nevertheless, in spite of the relatively low degree of refinement in the sawmill and the fact that the sawmills in general over time have a very low profitability, they are responsible for 70–80% of the forest owners' profits on the sale of timber. An increased upgrading of the sawn timber within the country is desirable from a national economic viewpoint – increased employment opportunities, increased export income, etc. It should then in the first place be for products with a higher added value, such as furniture and fittings. Today, the refinement value is 15–20 times higher for products from joinery and furniture industries compared to that of the sawn timber, and the added value of the wood within the building industry is only about 1.5 times.     

Integrated production of semi-finished components in sawmills,part I: External interactions

Abstract

In a changing business landscape, where globalization and new customer requirements create new business opportunities, some Swedish sawmills have taken over the production of components from their industrial customers. In light of the emerging network-centric perspective on business, sawmill managers' perceptions about component customers' operational requirements, customer interaction processes, and their sawmills' offerings are researched and discussed in this article. A multiple case study design, based on face-to-face interviews with Swedish sawmill managers and on various forms of secondary data, produced comprehensive information about sawmills' interaction processes with component purchasing customers. Thematic data coding facilitated the assessment of the research information in relation to the conceptual and empirical findings of previous research. The findings of the study indicate that more process orientation in housing-, joinery-, and furniture-manufacturing implies an opportunity for sawmills to make service-based offerings including not only physical goods, but also administrative services, logistics, and expert advice. The results of the study confirm the network-centric perspective on business where value is created through the interaction between firms. However, noteworthy barriers in the form of process-, culture-, as well as socially related factors at customer firms must be considered.     

Portable sawmills in a high-value rainforest cabinet timber industry in North Queensland

This paper examines the role and use of portable sawmills in north Queensland. Using a semi-structured questionnaire and personal interviews, the opinions of 18 operators of portable and fixed-site sawmills were canvassed on a number of issues including main problems faced by the local industry, current sources of timber, sawn timber recovery rates of their operations, willingness to purchase new milling and other equipment, opinions about why (or if) portable sawmills can sell timber at a lower cost than fixed-site mills, and destinations of sawn timber milled. The most critical issues faced by sawmillers were the lack of resource security and competing products, in particular competition from imported tropical timbers from neighbouring island countries including Papua New Guinea. Most sawmillers in north Queensland currently obtain logs mainly from private landholdings and are hesitant to invest in new equipment due to concerns about future log supplies. This paper also explores the current and potential role of portable sawmills in the regional small-scale forestry industry. An examination of policy issues suggests that there may be a need for new legislation to cover employees, sawn timber consumers and sawmillers themselves. The future role of portable sawmills may require a co-operative approach that emphasizes low volume value-adding, due to the decreasing supply of logs in North Queensland. This paper is based on research undertaken for a Master of Commerce by the first author (Smorfitt 2000). All authors are members of the Rainforest CRC, which has provided financial support for the research reported here. The assistance of Mr I. Venables in providing comment on the questionnaire for portable sawmillers is gratefully acknowledged.     

Production strategies in the Swedish softwood sawmilling industry

The strategic production decisions to improve profits for sawmills can be described in three main dimensions. More value-added production increases unit revenues, larger volumes reduce fixed costs per produced unit, and improved productivity reduces unit costs. Using data about the Swedish sawmills and cluster analysis, six groups of sawmills were defined with these strategy dimensions. Characteristics of each strategy are presented concerning ownership, location, technology, and economic indicators. The results indicate that different groups of Swedish sawmills employ different production strategies, which are reflected both in the dimensions, value-added shares, size, productivity, and by other technical and economic characteristics of the sawmills. The relationships between production strategy and profitability is also analysed and discussed.     

Automatic grading of sawlogs: A comparison between X-ray scanning,optical three-dimensional scanning and combinations of both methods

As sawmills become increasingly efficient, the importance of focusing on value recovery becomes obvious. To maximize value recovery, sawmills require the ability to sort logs according to quality. This study compares four different combinations of three-dimensional (3D) and X-ray scanning that can be used to grade logs automatically. The study was based on 135 Scots pine (Pinus sylvestris L.) logs that had been scanned with both a 3D scanner and an X-ray scanner with two X-ray sources. The percentage of boards with correct grade sawn from automatically graded logs varied from 57% when using only 3D scanning to 66% when using a combination of 3D scanning and X-ray scanning in two directions. The highest possible result, with ideal log grading, was 81%. The result also shows that the combination of a 3D scanner and one X-ray direction results in higher accuracy than a scanner based on two X-ray directions.     

Simulated yield and quality distribution of sawn timber from final felling in a Norway spruce [Picea abies (L.) Karst.] stand with varying thinning regimes: A case study

Abstract

An integrated simulation tool, formed by integrating the InnoSIM sawing simulation system with the RetroSTEM simulator, was used to convert available wood raw materials from final felling into sawn timber, allowing for calculation of the three-dimensional wood properties of individual stems (stem geometry, heartwood formation, knottiness) as well as the volume, quality and value of sawn timber in a Norway spruce stand with different thinning regimes (unthinned, normal and intensively thinned). Based on the input data of sawing patterns, the simulations indicate that there are relatively small differences (<8%) in the volume yield (m³ha^?1) of sawn goods resulting from sawlogs available from final felling with different thinning practices. However, intensive thinning yielded the largest stem diameters and the greatest volumes (m³ha^?1) of large-sized centre goods (thickness: 50, 63, 75 mm) of rather poor quality. Normal thinning yielded the largest volume of A-grade side boards and centre goods (m³ha^?1), as well as the best total value ([euro]ha^?1) of sawn timber. Differences observed in sawn timber quality distribution can contribute to even more significant variation in value yields, if pricing mechanisms of timber products change to favour higher grade timber products.     

Reconstruction of Pinus Sylvestris knots using measurable log features in the Swedish Pine Stem Bank

Abstract

The objective of this study was to develop a method for reconstruction of parametrically described whorls and knots from data possible to extract from industrial scanning of logs, using X-ray scanners. The method was conceived using the logs in the Swedish Pine Stem Bank as a foundation, and was based on a few predictor features extracted from these logs; namely whorl volume, distance between whorls and distance between pith and surface. These features were not measured in images but calculated from existing parameterised knots. Simulated test sawing shows that the reconstruction method results in a representative model of the knot structure in the log, when considering the grade distribution of the sawn timber produced by the simulation program. The results of this study could, for instance, be used for improved online quality predictions at sawmills. One step in this direction is to use industrial X-ray data to enlarge the amount of log data available for sawing simulation research. Future work can, therefore, focus on developing a practical application of the results presented here.     

A review on wood machining: characterization,optimization, and monitoring of the sawing process

ABSTRACT

Sawing is the most common machining process and is present in both primary and secondary wood transformation sectors. The objective of this paper is to review how it is affected by different factors. The current challenges associated with various machining factors, process monitoring, and sensor selection were identified and explained. Consequently, four research challenges and technological gaps were outlined. (1) Contradictory results have been reported due to different cutting processes, wood species, measurement methods, and cutting speed range studied in literature, so special consideration needs to be taken when comparing results with those available in the literature. (2) Laboratory test conditions cannot yet fully represent the extreme cutting conditions in sawmills. More emphasis should be placed on those harsh industrial cutting conditions. (3) Research on wood cutting lacks multi-objective optimization approach, which suggests that sawdust generation should be simultaneously analysed with surface quality and power consumption. (4) Compared with metal cutting, little research has been conducted on wood sawing monitoring using an artificial intelligence approach, which should be prioritized in designing adaptive control systems. Combining intelligent monitoring and multi-objective optimization approaches should pave the way for controlling the sawing process so higher surface quality and cost efficient machining is achieved.     

Factors affecting the fungal colonization of pine lumber

This study investigated whether the physiological condition of wood influenced patterns of colonization by mould and sapstain fungi. The extent of fungal defacement on sawn pine lumber Pinus nigra var. maritima that had been killed by gamma‐irradiation was compared with the defacement on untreated, still living timber that had been aged for up to 16 weeks prior to being sawn. All the sawn lumber was exposed to the natural inoculum of sapstain and mould fungi in a working sawmill environment over a 4‐week period. The results indicated that the pattern of fungal defacement differed markedly in dead or aged wood compared with untreated wood. Mould fungi were most prevalent on the dead irradiated wood, whereas sapstain fungi dominated the freshly sawn lumber which was still living. The differences appear to be independent of wood moisture content and may be related to the production of inhibitory compounds by living cells in wood as it becomes senescent and dies.     

Multivariate product adapted grading of Scots pine sawn timber for an industrial customer,part 1: Method development

ABSTRACT

Rule-based automatic grading (RBAG) of sawn timber is a common type of sorting system used in sawmills, which is intricate to customise for specific customers. This study further develops an automatic grading method to grade sawn timber according to a customer's resulting product quality. A sawmill's automatic sorting system used cameras to scan the 308 planks included in the study. Each plank was split at a planing mill into three boards, each planed, milled, and manually graded as desirable or not. The plank grade was correlated by multivariate partial least squares regression to aggregated variables, created from the sorting system's measurements at the sawmill. Grading models were trained and tested independently using 5-fold cross-validation to evaluate the grading accuracy of the holistic-subjective automatic grading (HSAG), and compared with a re-substitution test. Results showed that using the HSAG method at the sawmill graded on average 74% of planks correctly, while 83% of desirable planks were correctly identified. Results implied that a sawmill sorting station could grade planks according to a customer's product quality grade with similar accuracy to HSAG conforming with manual grading of standardised sorting classes, even when the customer is processing the planks further.     

Use of wood products in multi-storey residential buildings: views of Swedish actors and suggested measures for an increased use

ABSTRACT

Many studies have shown that wooden buildings in general have a lower climate impact than buildings built of conventional materials such as concrete and steel. In Sweden, however, only about 10% of the multi-dwelling buildings are built with timber frames. The goal of this empirical study is to provide a broad picture of the views of Swedish actors regarding the use of wood products in multi-storey residential buildings and suggest measures for an increased use. A questionnaire concerning the use of wood products in construction was sent out to Swedish developers, main contractors, and architects and 100 answers were received. The study shows that the views of the groups of actors differ in some respects and factors that may either facilitate or be obstacles to an increased use of wood products were identified and discussed.     

The Swedish hardwood sawmill industry: Structure,present status and development potential

Abstract

This study describes the Swedish hardwood sawmill industry with respect to its structure, raw material, production and market conditions in order to seek ways of increasing the competitiveness of the industry. Fifteen sawmills were studied through observations and interviews. The Swedish hardwood sawmill industry creates job opportunities in sparsely populated areas and uses a biological raw material which is important for environmental biological diversity. Any decrease in the use of this material will mean a drop in the incentive for forest owners to cultivate deciduous forests. Today, the hardwood sawmill industry is experiencing problems in securing the supply of raw material of the desired quality, i.e. without knots and discoloured heartwood (red-heart or brown-heart). To increase the competitiveness of the Swedish hardwood sawmill industry, the raw material supply must be secured. Production should be geared towards products demanded by the market, and new markets need to be entered.     

Schnittholzqualität und Furniereignung von Douglasien aus linksrheinischen Anbaugebieten

Summary Douglas fir sample trees from 9 various stands were cut in sawmills. Every board of the converted timber was graded; all defects in timber were analysed, especially all black and sound knots on the surface of the boards were measured. The percentage of good boards prooved to be comparatively low. From fertile sites the sawn timber quality seems to be inferior compared with wood from poorer and dryer sites. Douglas firs grown single between broadleaved stands showed the lowest timber quality. Throughout the quantity and thickness of black knots were responsible for poor quality. Experiments with production of veneer yielded useful carved veneers when sliced of quartered and clear logs. Branchless logs from 80 years old Douglas firs could be worked up to carved veneers, but are too young for peeled veneers. For full veneer logs diameters of 70 cm and structure of small annual rings is essential. For saw timber as well as for veneerwood production short rotation below 120 years is not suitable. Moreover pruning is necessary.      

Log sawing position optimization using computed tomography scanning

When disjoining a log, several factors affect the value of the sawn timber. There are log features, such as outer shape, knots, rot, and so on. There are also sawing parameters, such as sawing pattern, log position, and so on. If full information about log features is available, sawing parameters can be adapted in order to maximize product value in sawmills. This is soon possible, since computed tomography (CT) scanners for the sawmill industry are being realized. This study aimed at investigating how CT data can be used to choose rotational position, parallel displacement, and skew of sawlogs, to maximize the value of the sawn products. The study was made by sawing simulation of 269 CT scanned logs of Scots pine (Pinus sylvestris L.) and Norway spruce (Picea abies [L.] H. Karst.). The results showed that value recovery could be improved by 13% in average, compared to a sawing position based on log outer shape, and 21% compared to sawing logs centered and horns down. It can be concluded that a CT scanner, used in a sawline to optimize sawing parameters, has a large potential for increasing value recovery and thus profit.     

Improved ecoeffectiveness of interior hardwood products in the house-building industry as a way to promote sustainable forestry

Abstract

Sawn hardwood is required by the market to be homogeneous, even in texture and colour, but the products produced by Swedish hardwood sawmills exhibit a wide variation in characteristics. This makes it difficult for hardwood sawmills to find profitable markets for all their products. By developing new products with other properties for the building industry it may be possible to utilize hardwood more efficiently and increase the prices. This would result in higher ecoeffectiveness (defined as value in relation to environmental impact) of the forest-related business system by giving an incentive to grow deciduous forests, which leads to richer biological diversity. Diversity is fundamental to achieving sustainable forestry. At the same time, other less ecoefficient materials in buildings may be replaced. Exploring the requirements of the customers is essential before developing new products, in order to maximize the value of a product. In this study, the requirements of interior hardwood products in the Swedish house-building industry were studied in interviews and through questionnaires. The most important requirements, ranked higher than price, are delivery on time, shape stability, packaged products, rapid delivery and accurate moisture content. The results make it possible to focus on critical factors to gain market shares for hardwood as an ecoeffective building material.     

不同下锯法锯解的分析评价

本文就制材生产中通常使用的三种下锯法,采用计算机进行模拟锯解,然后进行分析评价,找出三种下锯法对主产锯材宽度、原木出材率和经济效果的影响。为合理利用原木、选择适当的下锯法,提供了理论依据。     

Yield Potential of Quercus robur Stands in Finland

Yield potential of common oak (Quercus robur L.) stands in Finland was examined by estimating the site index value with a Swedish model of a sample of 23 existing stands in southern Finland, and studying its correlation with site fertility and geographical location. Stand structure and yield parameters were compared with those suggested by the Swedish management regimes to assess their condition and potential for quality oak production. External wood quality and sawlog volume were examined in sample tree data. The study stands scored high site index values on the reference site index curves from southern Sweden. The most fertile sites showed an average site index value of H ₁₀₀=28-30 m, and the common Oxalis-Myrtillus type H ₁₀₀=24-26 m. In the absence of thinning and pruning, the external quality of the trees was poor. Defects had reduced the sawlog proportion on average by 40% from the estimated maximum allowed by tree dimensions.