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.     

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.     

Variation in log quality and prediction of sawing yield in oak wood (Quercus robur)

Context

The commercial feasibility of sawmilling depends on the expected volume and value of sawn planks. Models that predict the volume of sawn timber of a particular quality and produced from logs of known characteristics are therefore very useful.

Aims

The objectives were to study variation in sawing yield and to obtain models that predict lumber volume and grade recovery on the basis of easy-to-measure predictor variables of saw logs.

Methods

Forty-six oak trees growing in Galicia (NW Spain) were felled and cut into logs. The logs were visually graded and sawn mainly into quartersawn planks, which were dried, planed and visually graded for structural purposes.

Results

The total volumetric sawing yield was 47.6 %. The sawing yield for planks of structural dimensions (cross-section, 70?×?120 or 70?×?170 mm) was 43.4 %, but decreased to 8.4 % for structural sized and quality grade beams because of wane and biotic damage in many pieces. Log grade did not significantly affect sawing yield in the sample analysed, despite the wide range of diameter over bark at the smallest end in the sampled logs (22–77 cm). The sawing pattern affected total sawing yield (F?=?4.913; p value?=?0.001) and the sawing yield for structural planks (F?=?6.142; p value?=?0.0002); radial sawing with one cut and live sawing of half logs provided the highest yields. Three models were proposed for estimating sawn volume in timber products, with the small-end log diameter over bark as the predictor variable and R _adj ² between 0.31 and 0.78 (p value?<?0.01).

Conclusion

For the purpose of producing oak timber destined for structural use, the presence of bark and sapwood in planks must be reduced in the sawing process; this would decrease the total lumber recovery but increase the timber value yield. Air drying must be accelerated to reduce biotic damage in sawn planks. Geometric mean diameter over bark at the smallest end (d) outperforms other measures as a predictor variable for total or structural sawn timber volume.     

Rotational position of curved saw logs and warp of the sawn timber

With the development of scanning technology in sawmills, it is possible to optimise log rotational position when sawing. However, choosing a different rotational position than horns down might be detrimental for the board shape after drying, especially for curved logs. Thus, there is a need to investigate at what level of log curve it is possible to freely rotate logs without causing board warp. This study was carried out through a test sawing that was conducted at a sawmill situated in the middle of Sweden. The tests were made on 177 Norway spruce logs, with varying amount of curve. Half of the logs were sawn in the horns-down position, half were sawn rotated perpendicular to horns down. Log shape and warp of the dried boards were measured. The results indicated a relationship between board spring, log curve and choice of rotational position. Furthermore, board bow was related to log curve but not rotational position. It can be concluded that for straight logs, with a bow height of less than 15 mm, an unconventional rotational position does not cause excess spring in the boards. Bow and twist are not affected by the rotational position at all.     

Shape and distribution of knots in a sample of picea abies logs

In an attempt to develop a better understanding of the effect of knottiness on the yield of logs for sawn timber products, the present study examines the position and geometrical characteristics of 429 knots found in seven Norway spruce (Picea abies (L.) Karst) middle logs from southern Finland. The raw data used in this study were in the form of coordinates of points located on the knot surface recorded in a cylindrical (R, L, T) reference frame. The data were smoothed using a non linear three‐dimensional model. A curvature analysis of the knot pith was used to differentiate the curved and straight portions of the knots. This analysis made possible calculation of knot angles, symmetry, ovality and volume. The major finding of this study is the uneven distribution of knots around the log circumference. Nearly 50% of the total knot volume was concentrated in one‐third of the log facing the south‐east. Knots were also more prominent in higher portions of the logs studied. These observations support the argument that the uneven distribution of knots offers potential for improving the grade yield of timber sawn from trees harvested in high‐latitude countries.     

Potential for increasing volume yield by reducing planing allowance

About half the volume of sawlogs ends up as sawn and planed timber. The rest is lost due to drying shrinkage or is turned into by products. As the raw material is a major expense for a sawmill, it is important to reduce waste. To investigate how much the volume yield in the production of sawn and planed timber could be increased by reducing the target dimensions in the sawing stage in a sawmill, two groups of sawn timber were planed under similar conditions. One group consisted of sawn Scots pine timber with a large variation in twist. The other group consisted of sawn Norway spruce timber planed under different pressure settings. Using X-ray images, the minimum dimension for avoiding planer misses was calculated for each board, to find the smallest green target dimension. This was compared to actual measured dimensions. It was found that most sawn timber had unnecessarily large dimensions, and it was also found that a reduction in the target dimensions could increase the volume yield for sawn and planed timber by more than 3 percentage points. Boards with large twist would however need a higher planing allowance. The effect of the planer pressure setting was negligible.     

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.     

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。     

制材设备的发展及趋势

笔者从世界各国森林资源状况、制材产品和制材工艺技术发展的角度,围绕世界制材行业高生产率、高出材率、高木材利用率、高成材质量、高附加值和多产品品种的发展特点,分析了制材设备的发展及趋势:1)传统制材设备向数控化、智能化方向发展;2)为满足森林资源和制材产品变化,制材设备向多样化发展;3)为适应制材工艺技术的发展,制材设备向柔性化、创新化发展。这将为我国木材资源的高效利用和制材工业又好又快的发展提供有益借鉴。     

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.     

Choosing green sawing dimensions for Norway spruce from stochastic simulations

The high accuracy of log positioning and the stability of saw blades in breakdown machinery in modern sawmills have reduced the need to add margins for sawing variations. Oversize green sawing dimensions are still needed, but mainly to allow for drying shrinkage. This has put a new focus on better adapting green sawing dimensions to the shrinkage behavior of wood. In this study, a method for optimization of green sawing dimensions using stochastic simulation is presented. Normal distributions were generated for planed dry dimensions, kerf width, and target moisture content. The minimum share of boards exceeding the specified dry dimensions was decided, and deformations in boards from all positions in the cross section in a number of logs were simulated. The simulated shrinkage allowance from stochastic simulations was compared to experimental results from an industry test and to finite element results based on material data for Norway spruce. The results showed that the green width of the sawn boards should increase when the number of boards in the center yield increases. The green thickness of boards should be thinner for center boards and outer boards than for inner boards.     

Influence of growth stresses and material properties on distortion of sawn timber — numerical investigation

? The board distortion that occurs during the sawing and the drying process causes major problems in the utilisation of sawn timber. The distortion is highly influenced by parameters such as spiral grain angle, modulus of elasticity, shrinkage, growth stresses and sawing pattern.

? In this study a finite element simulation of log sawing and timber drying was performed to study how these parameters interact to affect board distortion. A total of 81 logs with different material combinations were simulated. From each simulated log four boards with different annual ring orientation were studied.

? The results showed that the elastic modulus, shrinkage coefficient and growth stresses had a large influence on the final bow and spring deformation. After sawing of the log into boards, the release of growth stresses was the main contributor to the bow and spring deformation. For boards with low modulus of elasticity, the bending distortion became larger than for the boards with high modulus of elasticity. The twist deformation was very small after sawing but increased significantly during drying of the boards. The results showed that spiral grain angle and the board location within the log were the main contributors to the twist deformation.

     

The use of the first industrial X-ray CT scanner increases the lumber recovery value: case study on visually strength-graded Douglas-fir timber

Key message

Industrial computed tomography scanning of logs provides detailed information on timber quality prior to sawing. A sawing simulation—considering log rotation angle and knot size accuracy—revealed an average value increase of up to 20% for the best angle compared to the conventional horns-up position.

Context

Computed tomography (CT) scanning has the potential to improve the value of products sawn from logs and meets the increasing demands of the wood industry for detailed information on log quality prior to processing.

Aims

In a validation step, automated measurements of knot cluster variable DAB (DIN 4074-1:2012-06) using CT were compared with manual measurements. In a second optimization step, the hypothesis that the value of the sawn products is increased by sawing at the best rotation angle as opposed to the horns-up position was tested.

Methods

A sample of 36 Douglas-fir logs were scanned in an industrial CT scanner, and sawn into boards. Knots on the boards were manually measured, and compared with the corresponding knots on virtual boards created from the CT data. The error of the DAB was measured by comparing CT data to manual measurements. An optimized sawing simulation was performed, using the measured DAB error to account for CT measurement errors, as well as a rotational error to account for errors in the log turning equipment. Using the results of the sawing simulation, Monte Carlo simulations were performed to show the potential and benefit of an industrial CT scanner.

Results

The three largest DABs measured by the CT showed good correlation to the measurements on the manual boards. The simulation revealed an average increase of value from 4 to 20% compared to the conventional horns-up position depending on the relative price differences between the strength grades.

Conclusion

By using a CT scanner to optimize sawing, sawmill owners can process logs in a better way to produce final products with increased added value.

     

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.     

Structural development of Pinus sylvestrís stands with varying initial density: A preliminary model for quality of sawn timber as affected by silvicultural measures

The effects of stand density, thinning and pruning on the quality of sawn timber of Scots pine (Pinus sylvestris L.) were studied based on a computer model. Procedures for the tree growth and crown structure produce a tree, whose properties in terms of location, dimensions and quality (living, dead) of branches are known for any moment of the selected rotation. Consequently, the size, quality (living, dead) and location of knots in sawn timber are recognizable allowing the grading of sawn pieces. The model computations showed that the natural dynamics of the crown system in narrowly‐spaced stands could yield sawn timber nearly of the same quality as resulted from pruning in widely‐spaced stands. Thinning increased the branch growth and the branchiness of the wood yielding lower grade for sawn pieces, respectively.     

Optimization potential for perception-oriented appearance classification by simulated sawing of computed tomography-scanned logs of Norway spruce

Abstract

Wood, as a natural material, has favourable properties in both technical and aesthetic aspects. Due to its inherent variability, production of high-quality sawn timber demands adequate control of log conversion, which is feasible with computed tomography (CT) log scanning. Existing appearance grading rules for sawn timber might not fully reflect people's visual perception of wood surfaces, and therefore, an alternative, more perception-oriented appearance classification could be beneficial. An appearance classification of sawn timber based on partial least squares discriminant analysis (PLS-DA) of knot-pattern variables was developed and tested. Knot-pattern variables derived from images of board faces were used in training PLS-DA models against an initial classification of the board faces previously established by aid of cluster analysis. Virtual board faces obtained from simulated breakdown of 57 CT-scanned Norway spruce logs were graded according to the developed classification. Visual assessment of the grading results indicated that the classification was largely consistent with human perception of board appearance. An initial estimation of the potential to optimize log rotation, based on CT data, for the established appearance grades was derived from the simulations. Considerable potential to increase the yield of a desired appearance grade, compared to conventional log positioning, was observed.     

Analysis of sawn lumber production from logging residues of branchwood of <Emphasis Type="Italic">Aningeria robusta</Emphasis> and <Emphasis Type="Italic">Terminalia ivorensis</Emphasis>

One way of meeting the supply demands of the wood industry is through the reduction of waste in timber processing. It has been estimated in Ghana that for every tree felled, nearly 50% of the tree volume is left in the forest in the form of branches, crownwood, and stumps. In this study, the potential of utilizing branchwood as raw material from logging residues to help meet the timber demands of the downstream processing sector was analyzed experimentally. The sawing characteristics of the branchwood of Aningeria robusta and Terminalia ivorensis with diameters in the range 10–25 cm using live sawing and cant sawing methods were determined using a randomized complete block design, 2 × 4 factorial with three replications. Experimental results indicate that, the relative lumber value yields for first and second grade boards of A. robusta and T. ivorensis branches were 25 and 20%, respectively, while the green lumber volume yields were 40 and 32%, respectively. A high proportion of sapwood and the occurrence of washboarding in T. ivorensis contributed to that species’ relatively low lumber value and volume yield. The experimental results further indicate that the sawing technique used had no significant influence on lumber yields. However, at 5% level of significance, significant differences in lumber yield existed between some of the diameter classes.     

Erfahrungen über die Auswirkungen längerer Wasserlagerung auf die Qualität von Nadelstammholz

Summary Unbarked windthrown softwood timber was stored in water for about two years and during that time the protection effect against storage decay has been tested at certain intervals. The moisture content of the seperately swimming logs did not change remarkably in the interior of the stems, only from their ends some water has diffused into the wood. Apart from a small light red-brown discolouration in consequence of the penetration of tannin from the bark into the wood, which has no economical effect, in all these logs not any injuries caused by fungi, insects or cracks could be observed. When the logs are piled in more layers, the stems of the upper layers dried faster and showed all the wellknown storage damages. Provided that timber is sawn soon after the landing, water storage can be considered as an effective mean to prevent degradation during storage, but if sawing is retarded, the wood will be attacked by insects and fungi as well as the stems stored in forests after felling.      

基于数字图像处理的樟子松锯材分级研究

为了解决传统锯材检测方法效率低、劳动强度高和人为因素影响大的问题,笔者运用数字图像处理的方法对樟子松锯材等级进行检测,实现樟子松锯材等级检测的标准化和程序化。根据樟子松锯材缺陷与天然木纹颜色存在显著差距的特点,利用Otsu's方法的最佳全局阈值处理锯材图像得到最佳分割阈值,获得锯材的二值图像,得到缺陷位置像素坐标,将缺陷坐标与锯材实际尺寸对应,计算出相应锯材的净划材尺寸和出材率,完成对锯材等级的划分。利用该方法对75片试件进行表面质量检测和等级划分的准确率为94.67%,分级程序的运行时间约为1.793 s。该方法在保证检测准确率的情况下不仅可以减少检测时间、降低人工劳动强度、提高检测准确率,而且解决了人工检测主观性强的问题。     

The flexural properties of young Pinus elliottii x Pinus caribaea var. hondurensis timber from the Southern Cape and their prediction from acoustic measurements

The objectives of this study were to determine the bending strength and stiffness properties of young Pinus elliottii x P. caribaea var. hondurensis timber from the Southern Cape, South Africa, and to evaluate the predictability of these properties from acoustic measurements on standing trees, logs and their sawn boards. The timber has good bending strength (MOR) properties but the mean stiffness (MOE_stat) was significantly lower than that required for structural-grade timber. The mean MOE_stat was also about 30% lower than a P. radiata control sample. The MOE_stat of sawn boards could be predicted from acoustic stress wave measurements on standing trees with a correlation (r) of 0.48 and from acoustic resonance frequency measurements on sawn boards with a correlation of 0.85. The MOR of sawn boards was not significantly correlated with acoustic stress wave measurements on standing trees and only moderately correlated with acoustic resonance frequency measurements on sawn boards (r = 0.45).