PlyVisions 104

PLYVISIONS
RAUTE CUSTOMER MAGAZINE 1/2004
Focus on productivity:
Smart solutions
Composer upgrade
Automatic veneer patching
IP Wood
Industrias Monzón
contents features
4
7
10
14
18
21
24
28
32
34
36
2
Many of the Russian participants
expressed the opinion that the Safari
gave them ideas that will help them
to solve their production problems
and create more modern and efficient
plywood manufacturing operations.
Smart solutions.
Russian plywood
producers on safari
in Finland.
Raute R&D
really produces.
Composer
upgrade increases
productivity…
Automation veneer
patching.
“As the applications
for automatic veneer
handling expand in the
future, special attention
will be placed on all
aspects of quality”,
says Mr. Jouko Pussi.
Win new customers
with overlaying.
IP Woods, Mr. Sandy McCorvey
explains: “With the hands-on
training provided by the other
IP mills and the training
material provided by Raute,
our team members were more
than ready to go once the
equipment became operational”.
Raute stacks
up for IP Wood.
Monzón's poplar
plywood business
enjoys fair winds.
Raute celebrates 20
years in Singapore.
Cooperation
improves quality.
Trade shows
and fairs.
Cooperation between
Raute and Industrias
Monzón began following
a visit by Raute’s
representative in Spain.
PLYVISIONS
Published by RAUTE OYJ, P.O. Box 69, 15551 Nastola
Finland. Tel: +358 3 82 911, Telefax +358 3 829 3200
Editor-In-Chief: Merja Hakala. Editorial Group: Matti Aho, Merja Hakala,
Ulla Hillu, Seppo Leppänen, Mika Hyysti, Erkki Kauranen, Rick Massey,
Jussi Toivio. Layout and art work: Non-Stop Studiot Oy, Paul Hitchman.
E-mail: [email protected] /www.raute.com
Cover Photo: Veli-Matti Lepistö
Copyright RAUTE OYJ, All Rights Reserved.
Reproduction permitted with permission from Raute Oyj.
ISSN 1459-3165
Recovery
Productivity
Profitable
panel
production
Quality
Capacity
Dear Reader,
Since our last PlyVisions, we’ve seen considerable change. Risto Mäkitalo resigned as
President and CEO to pursue personal business interests. During his time at Raute the
wood-based panel industry witnessed years of
strong growth and periods of deep recession.
However, regardless of the business climate,
Risto never lost focus on the importance of
product and technology development. Even
when faced with marginal business results,
Raute maintained a healthy level of R&D
investment. We are all grateful to Risto and I
want to extend my thanks to him on behalf of
Raute and, I am sure, our customers.
I also want to thank our employees
and customers for their efforts and the trust
they continue to show in our company. I
believe it is that trust, as well as Risto’s legacy,
that gave Raute’s Board of Directors the confidence to recruit me from within the company
as the new President and CEO. For me this is
a great opportunity, both personally and professionally. Certainly, I realize that no single
individual will be responsible for Raute’s success. It will take input from many sources, not
least of which will be solid co-operation with
those to whom we are ultimately responsible,
namely, our valued customers.
PLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
Our theme for this issue of PlyVisions is
“productivity” - getting the most out of
your resource and production process.
The diagram above illustrates the critical
drivers behind sustainable profitability in
panel production, with one of the key elements being a mill’s ability to maximize
recovery; both in terms of volume and
quality. For this we look towards products
such as Raute’s Smart-Scan XY+, a block
optimization system that increases veneer
recovery as well as reducing random and
maximizing face sheet recovery. Interest in
this new technology has been strong with
four installations currently underway.
You can also read about the most
productive automatic veneer patching system in the world: the 72,000 patches/shift
Patchman installed at UPM’s Pellos mill in
Eastern Finland.
Other articles highlighting productivity improvements include peeling line
modernizations, improved composing,
colour scanning, stacker controls upgrades
and improvements in panel pressing. All
these projects have two things in common
- the customer’s desire to improve productivity and quality and Raute’s solution.
We will also introduce you to Raute
Research, where our innovations take
shape and form and where we undertake
testing on a wide range of our customers’
raw materials.
This issue is being published to
coincide with the Lesdrevmash Fair in
Moscow. Russia is presently experiencing
the strongest growth in plywood production of any region in the world, making
it an important market for Raute and a
challenging competitor to other plywood
producing countries. We anticipate an
interesting trade event and look forward to
providing a report in our next issue.
In the meantime, please enjoy
PlyVisions and continued success in your
business.
Tapani Kiiski
President and CEO
Raute Oyj
3
“Smart
are the key to pro
Raute provides a multitiered process control
and automation system
that utilizes intelligent
PLC technology to
assist mill management
in production planning,
production control,
process monitoring,
and parameter setting.
We call it “Smart
Solutions”.
BY RICK MASSEY, PHOTOS VELI-MATTI LEPISTÖ
Recently-appointed President & CEO, Mr.
Tapani Kiiski, has been directing development of Raute’s process automation
capabilities. He shares his thoughts on the
need for greater process automation in the
plywood industry and the steps Raute is
taking in that direction.
4
t Solutions”
ductivity and profitability
“The plywood industry has to improve in
order to be competitive against products
that would take market share”, Tapani stated from his office in Nastola, Finland.
“Today, the key requirements are
to increase recovery, improve quality,
and achieve greater productivity. Positive
results will enable you to reduce costs,
improve productivity and get a higher
price for your products. Then you will
realize better profitability”, he added.
Tapani believes that machines are
only part of the equation. The key is
how well they perform, how they meet
their design potential and the results
they deliver and he is in a good position
to know. Before coming to Raute, Tapani
was a senior executive at KCI Konecranes
where he had responsibility for technology
development. KCI is a global force in crane
and crane maintenance technology.
“In Raute’s case, we have strengthened our position through innovation and
solid customer service. Now we are bringing to the forefront our considerable skill
in process automation”.
According to the CEO of Raute,
process automation is a less obvious element in plywood manufacturing, being
less visible than the massive iron structures typically found in plywood mills.
“One doesn’t have to look far to
see the successes enjoyed by the growth in
process automation in the plywood industry”, he stated enthusiastically. “Consider
increased recovery. With XY block optiPLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
mization, green veneer moisture analysis and intelligent clipping, recovery has
advanced, particularly in the areas of full
sheet and face veneer recovery.”
As to improved quality, Raute’s
new chief executive is equally positive.
“Quality improves with advancements in
process automation. Two major challenges
to productivity are low quality, small
diameter raw materials and plantation
wood. However, with improvements in
lathe design, such as Raute’s new SmartPeel lathe incorporating Optimal Peeling
Geometry (OPG), these challenges are
being met and quality improvements are
being made”.
“Advanced vision technology is
also important, ensuring that veneer is
correctly graded and that the higher grades
are not wasted in the core plies. This is
another example of how process automation is improving quality and raising
productivity.”
As to the need for increased productivity, Tapani believes it isn’t possible
without advanced process automation.
“As production rises, the ability of
human operators to keep pace declines.
Mills can add labor, but that raises costs.
Only machines equipped with process
automation capabilities can keep pace.
For example, our stackers automatically
separate green veneer into full sheets and
randoms, and stack according to moisture
content, and at speeds that are far beyond
human capabilities. Advanced automa-
tion also reduces the dryer bottleneck.
For example, data from a Raute moisture
analyzer is used to control the speed
of the dryer, while automatic humidity control maintains the optimal drying
environment. All this raises quality and
productivity.”
As to improving profitability,
Tapani believes that lowering production
costs will have the biggest effect.
“Raw material costs are rising and
consumers want better products at less cost.
Competition is hard and margins are tight.
The good news is that we are developing
technology that will help bring down production costs. This is our “Smart Solutions”
approach to manufacturing and it benefits
our customers in several ways.”
Tapani cited other examples of
how plywood producers might improve
productivity and be more profitable.
“Consider how you might add value to
your basic production by overlaying, for
example. A market exists globally for this
technology and profits can be good.”
“I hope I have been able to give you
some idea of what I believe is the value
of implementing “Smart Solutions” in
your plywood and veneer manufacturing
processes. By doing so, I believe, you will
improve operating efficiency and become
a more productive and profitable plywood
producer. I invite you to read the following
“Smart Solutions” offered by Raute and to
consider the measurable benefits you can
expect in your mill.”
continues overleaf...
5
”Smart Solution”
Smart-Scan XY+
Key Feature
Measurable Benefit
Laser curtain that provides over 8,000 measuring
points to ensure precise block optimization during
peeling.
- Greater recovery
- Less round-up
- More full sheets, less random
3D imaging of the block identifies protuding knots,
enabling automatic knife carriage positioning
- Reduces carriage travel
- Less idle time between peel cycles
- Increased production
Virtual peeling that determines the exact moment
when the head closes and the knife contacts the
block
- Reduces round-up waste
- Optimizes recovery
Lathe continues to peel during automatic calibration
of the spindles (optional feature)
- No wasted production time
- Greater utilization of the lathe
Smart-Peel Optimal
Peeling Geometry
(OPG)
Precise control of the key peeling parameters
to ensure that they all perform their tasks in a
synchronized manner:
- block centering
- knife carriage feed
- knife gap adjustment
- block drive and position control
- digital pitch angle control
Green veneer
moisture analysis
Accurate measurement of moisture in green veneer
enables moisture clipping, moisture sorting
- Limits clip loss at the clipper - higher recovery
- Separates veneer by moisture content %
- Improves drying efficiency - greater production
- Reduces overdry - improves veneer quality
- Reduces redry - greater production through the dryer
Random handling
and stacking
High-speed random selector that automatically
separates full sheets, random and trash
- Reduces production costs by eliminating labor
- Increases recovery of random veneer
Smart stacker
controls
Intelligent PLC and ”Smart-Ware” - proprietary
Raute software that enables high-speed scan times
for improved knock-off accuracy and simpler tuning
- Improved stacking accuracy - green and dry
- Squarer loads - less damage
- Improved dry end productivity
Smart dryer controls
Bringing all drying parameters - speed, damper
control, moisture control - under a common PLCcontrolled umbrella
- Touch-screen control eliminates guesswork
- Operator’s role is to monitor
- Increased dryer production
- Better moisture control lessens overdrying, redrying
- Improved dry veneer quality
Camera grading
Replacing grey-scale grading with color grading
- Identifies all open defects and defects based on color
- Precise grading
- Veneer properly identified for quality
- Proper utilization = better profitability
Improved composing
New method of composing that produces a tighter,
less visible joint
- Composed veneer can be used as face material
- Better utilization of veneer
“Smart Clip”,
intelligent clipping
Enables the composer to operate in a “clip, no-clip”
mode.
- Only clips if necessary - improves recovery
- Enables greater production through the composer
Automatic veneer
patching
Camera determines type and location of defect in
dry veneer and provides coordinates to patch head
- Patches according to parameters set by mill
- No overpatching = higher productivity
- Minimal supervision = lower production costs
- Uniform patching = better quality patched veneer
Mill-wide MIS system
All production reporting is available at a single
operator station that is accessed through Ethernet
connection running throughout the mill
- Single-point management station
- More efficient utilization of human resources
- Instant verification of performance parameters
- Full reporting capabilities
- Management decisions based on accurate data
6
- Precise thickness control
- Fewer spin-outs
- Improved veneer quality
- Increased recovery per block
Russian
plywood
■ The purpose of the
Safari was twofold - to foster
relationships between Raute
and members of the Russian
plywood industry, and to expose
Russian producers to new technology and innovations.
producers on safari in Finland
BY VLADIMIR SHVETS,PHOTOS: VLADIMR SHVETS, VELI-MATTI LEPISTÖ
The Russian plywood industry has enjoyed steady growth over the past few
years and 2003 was no exception. Growth for the year was an impressive 7.6%
compared with the previous year, an increase attributed to stronger internal
demand compared with the strong growth in exports during previous years.
The strengthening of the Russian currency, which is now freely convertible,
saw prices rise to comparable levels for both domestic and export products
with the result that sales of medium grade plywood became of greater interest
to the local producers.
PL
LYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
7
■ The group spent two days at Raute’s head office where they heard presentations on plywood manufacturing technology.
Given the strong market conditions that
many Russian mills enjoyed in 2002, last
year saw the emphasis among producers
on increased production and more flexible production.
With these favorable market conditions and strong interest on the part of
Russian plywood producers, Raute took
the opportunity to host a Wood Safari
from 8 to 13, March. The visit to Finland
took place following the dedication in
St. Petersburg of Raute’s Representative
Office located on the premises of the State
Technical Forest Academy. There were 40
participants, the majority of whom came
from Russia’s plywood industry and financial establishments.
The purpose of the Safari was
twofold - to foster relationships between
Raute and members of the Russian plywood industry, and to expose Russian
producers to new technology and innovations that have made Finland one of the
leading producers of plywood and related
products in the world.
According to Ms. Ludmilla Bobrova
of the Ust-Izhora Plywood Mill, “It was
very interesting to have a fresh look at the
Finnish plywood industry, especially at the
changes that have taken place over the past
five years. The Safari enabled us to learn
8
about the trends in panel manufacturing,
especially in overlaying and new peeling
technologies.”
With such a big group to escort,
it wasn’t always possible to keep everyone in one place at one time. Everybody
discovered something new in overlaying,
plywood production, automation and glue
preparation and so there were many fields
of interest during our visit to the mills.
Technology managers were particularly interested in new machinery, engineers
focused on production lines and everybody
found something of particular interest that
caught their attention.
The group spent two days at Raute’s
head office where they heard presentations
on plywood manufacturing technology.
They also viewed Raute’s factory in operation and some participants were even able
to see machinery they had ordered in
partial assembly. A highlight for many
was having the opportunity to learn more
about LVL manufacturing, especially since
there is only one LVL producer in Russia
whose mill is located in Siberia, far from
Western Europe.
Discussions among the Safari participants most often centered on how to
produce plywood more efficiently, how
to increase veneer recovery and how to
apply the technology they had observed in
the Finnish mills. Of course, comparisons
were drawn between the two industries
and the common challenges they face. Like
Finland, Russia is facing rising raw material costs. In Russia, however, the need to
modernize aging machinery and how to
make production more efficient has created its own set of challenges.
The five days of the Wood Safari to
Finland flew by quickly but the impression
has been lasting. Many of the participants
expressed the opinion that the Safari gave
them ideas that will help them to solve their
production problems and create more
modern and efficient plywood manufacturing operations.
Many thanks to the Raute staff
who helped make this 2004 Russian Wood
Safari to Finland a success - Astrid VähäTouru, Pirjo Salomaa, Kimmo Ahonen,
and Kimmo Suomalainen. ●
■ Everybody discovered something new in overlaying,
plywood production, automation and glue preparation and so
there were many fields of interest during our visit to the mills.
■ Discussions among the Safari participants most often
centered on how to produce plywood more efficiently.
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PL
LYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
����
Plywood is one of the fastest growing
and most profitable segments of Russia’s
forest products industry. From 1999 to
2002, the growth in annual production
averaged 14%. On average, two-thirds
of production is exported, the major
destination being the United States.
Birch, at 85%, continues to be the major
wood species processed. Pine, larch and
aspen make up the balance. In all, there
are 50 plywood mills in Russia, five of
which produce in excess of 100,000 m³
per year. The biggest producer is Sveza
Group with a 15% market share.
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9
Raute R&D really produces
BY RICK MASSEY
10
With 55 million m³ being produced annually, plywood remains one of
the most important structural panel products on the market. In order to
remain at the leading edge of plywood manufacturing technology, Raute
continues to invest in developing products that improve the profitability and
competitiveness of plywood producers globally.
Research and development plays an important role in Raute’s business,
as evidenced by the modern facility that greets visitors to our plant in
Nastola, Finland.
The 2,500 m² Raute Research facility
can accommodate 50 staff. In addition
to having space available for assembling
and testing machinery, the facility also
undertakes testing of a wide range of raw
materials.
From paper to practice
Ideas guiding product development come
from many sources, but mostly in response to
changes in resources and customer needs:
Changing resource base
●
Small diameter wood
(as small as 150 mm or 6”)
●
Plantation species
(fast growing, pruned)
●
Alternative species (Radiata
pine, eucalyptus)
●
Region-specific species (technology to match local conditions)
Changing customer needs
●
Need to be price competitive against alternate products (OSB, MDF)
●
Need to be more productive
(do more with less - smaller
diameter resource, lower quality)
●
Need to improve recovery
(waste no longer acceptable, small core peeling)
●
Need to reduce maintenance (greater reliability,
more service support)
●
Need to improve product
quality (high peel quality
from low quality resource)
●
Need for better profitability
(higher selling price, better ROI)
●
Need to reduce labor (reduce
manhours/m³ of production,
higher levels of automation)
PLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
This approach was behind the
development of our new Smart-Peel lathe.
The concept was tabled in the late 1990’s;
development work began in 2000 and
the lathe was ready for testing in 2003. A
year later it has proven its merits and two
Smart-Peel lathes have since been sold,
the first of which will be installed later
this year.
Another recent innovation, which
was designed, built and tested at Raute
Research is the fully-automatic plywood
8x8 layup line. Due to the large size of
the sheets, it was determined that manual
handling of the veneers could injure operators and damage the veneer. The high level
of automation offered by the layup line
ensures that the mill satisfies its production targets while eliminating the potential
for damage to personnel and materials.
The line has been in service for over a year
and interest in fully-automatic layup, for
both plywood and LVL, is strong.
Vision technology
Vision technology forms an integral part
of Raute’s product base, one that commands considerable investment in R&D.
At the Mecano facility in Kajaani, Finland,
vision engineers are charged with the
responsibility of overseeing current and
future technological development while
at Raute Research in Nastola, the emphasis is on the mechanical applications. At
Raute’s plant in Vancouver, Canada, North
11
■ A combination VDA/DMA
(veneer defect analyzer/dry veneer
moisture analyzer) at the Mecano
facility in Kajaani, Finland.
12
American customers have access to our
Vision Technology Center, where their
raw materials can be tested and hands-on
training is carried out. Raute offers these
services at all three locations.
Testing available
Another important function of Raute
Research is raw materials testing.
Recently, testing was undertaken on
behalf of Gunns Limited to determine
the suitability of their eucalyptus for making rotary peeled veneer. Gunns’ policy is
to process each log to its maximum value
and rotary peeling was seen as another
form of value adding, which could benefit
the company and its owners.
Established in 1875, Gunns is
Australia’s largest fully integrated hardwood products company, operating sliced
veneer mills, sawmills, planing mills,
flooring plants and woodchip facilities in
Tasmania, Australia’s southern-most state.
The company also has a veneer plant in
New Zealand, sawmilling operations in
Western Australia and distribution stores
throughout Australia.
Each year the company processes
over 4 million tonnes of logs into a range
of products that include: eucalyptus woodchips for fine paper, sliced decorative
veneer, sawn lumber, flooring, mouldings,
laminated beams, and kitchen cupboard
doors, among others.
Tasmanian eucalypts are renowned
for their superior strength characteristics and the management at Gunns felt
that rotary peeled eucalyptus veneer from
Tasmania had the potential to assist LVL
manufacturers who want to improve the
strength characteristics of their product.
As part of the process of selecting a
suitable machinery supplier, Gunns’ management asked Raute to conduct peeling
and gluing trials.
Norwegian Spruce veneer was
sent from New Zealand, together with
Gunns’ own Eucalyptus Obliqua, to Raute
Research in Finland. Sample panels were
made on Raute’s laboratory press, after
which immersion and boiling tests were
conducted on the samples to determine
the correct PF glue bond. All samples
had a very high wood failure percentage,
which indicated that the correct bond had
been achieved.
Strength testing was carried out on
samples measuring 1,400 mm x 2,500 mm
(4 x 8 ft) in accordance with recognized
international standards. Testing showed
that the addition of four eucalyptus plies in
the LVL layup improved the most important strength constituents of the product
compared with 100% spruce. Raute’s Mr.
Andre Klemarewski, who oversaw testing,
believes the results were positive.
“Under conditions of normal LVL
production, veneers will be strength tested
prior to layup and values assigned that
determine the layup sequence”, said Mr.
Klemarewski. “In this case, however, no
strength testing was carried out prior to
layup and so the veneer strengths were
mixed”, he added.
rial resource, we know we can successfully
peel and dry rotary eucalyptus veneer and,
thanks to Raute’s testing facilities in Finland,
we know we can glue our product in conjunction with a number of other species.”
Added Mr. Stevenson, “The next
and somewhat significant step is to find
suitable partners in the LVL industry that
are in need of a rotary peeled product that
will add significant strength to the LVL
they produce.” ●
■ The research team examines pressed eucalyptus panels.
■ Complete processing lines, such as
this 8x8 automatic layup line and a complete
Smart-Peel peeling line, can be assembled and
tested at Raute Research.
Mr. Klemarewski saw the results
as being favourable with respect to the
opportunities for utilizing peeled veneers
made from Gunns’ eucalyptus to strengthen LVL.
“The results were conclusive.
Eucalyptus Obliqua LVL has a bending
strength up to 50% higher than Norway
Spruce LVL. In addition, the bending
strength of Spruce LVL can be significantly
improved with the addition of Eucalyptus
veneer. And, both types of PF adhesives used
in the testing produced very good bonds,
including 100% Eucalyptus LVL”.
Asked to comment on the outcome
of the testing, Mr. Graeme Stevenson,
General Manager of Timber for Gunns
stated, “To date, Raute have shown themselves to be most helpful in what has been
a learning process for both companies.”
“We (Gunns) are now at the point in
the project where we have a secure raw matePLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
■ Eucalyptus samples after glue bond tests had been carried out.
13
Composer
upgrade
BY MIKA HYYSTI
increases productivity,
14
Raute delivered its first core veneer composer in 1991.
Since then, over 100 units have been sold worldwide
to customers in North and South America, Europe,
Australasia and Asia.
Raute composers typically handle a
quality and yield
variety of veneer species in thicknesses
ranging from 1.5 mm (1/16”) to 3.2 mm
(1/8”).
Machines have been built to handle
veneer lengths up to 3,050 mm (10 ft.). In
all cases the composer has proven its ability to produce composed core veneer that
meets mill standards for automatic layup
and further handling.
Now, as part of our ongoing program of R&D, we offer a veneer composer
upgrade package that provides greater
productivity, improved sheet quality and
higher material recovery.
The results are:
●
less clip loss due to
– precise alignment,
– improved veneer
thickness detection, and
– improved clipping accuracy,
●
removal of "hidden" defects like
blue stain, rot pockets and bark,
●
more operational time
between maintenance, and
●
higher speed.
Special attention has been paid to
making certain wear items and critical
components more accessible and more
reliable. Higher speeds are possible due
to the Smart-Clip function and advanced
automation.
PLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
15
■ Diagram 1.
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Higher recovery is due to precise servo-alignment, which aligns the
veneer ahead of the clipper to avoid severe
bias clipping (see Diagram 1). Further
improvement is provided by the SmartClip function that assesses the quality of
the leading edge and the squareness of the
sheet and instructs the clipper to clip only
if necessary.
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■ Graph 1
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■ Graph 2
16
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Precise thickness control and
defect recognition
The upgrade provides more accurate
thickness measurement, taking thickness measurements every 300 mm (12”)
along the leading and trailing edges of the
veneer. Testing has proven this method of
thickness detection to be highly accurate.
On 1.5 mm (1/16”) thick birch veneer,
accuracy is in the range of -0.1 to +0.3
mm (-0.004 to +0.012”), and on softwood
veneer less than 2.6 mm (1/10” thick),
the figure is -0.3 to +0.4 mm (-0.012 to
+0.015”). Thickness sensors and a high
resolution camera combine to detect even
the smallest defects.
Defects like mineral stain, rot pockets or bark are marked by the operator
using a luminescent marker. The scanner
then reads these marks and instructs the
clipper to remove the defect.
Components
Thickness control consists of multiple
measuring heads and pneumatic cylinders. A reference sensor is also supplied,
together with belt guides and necessary
software.
Servo-squaring uses photocells, a
servo-motor and servo-wheel. Skew correction of up to 100 mm (4”) is typical on
random widths up to 300 mm (12”).
Smart-Clip uses a camera to determine the squareness of the veneer. This
data instructs the clipper to either clip the
■ Photo 1
edge of the veneer or let it travel through
to the glue heads without clipping.
The luminescence detector includes
sensors for each length of veneer, cables
and fittings and necessary software.
The new style servo-clippers and
tipple create less impact on the components, less component wear and a 10%
increase in speed.
An industrial PC with a highresolution line scanning camera is used
to remove defects from the veneer and to
provide a graphical user interface for making parameter changes (see photo 1).
PLC control is used to control basic
functions of the composer including the
possible customizations of the composing line like different infeed and outfeed
conveyors and stackers.
Higher recovery
Older composers often clip too much
veneer due to poor veneer alignment
and the absence of a reliable method of
determining the quality of the leading
and trailing edges and the squareness of
the veneer.
Graph 1 shows the accumulated
length of veneer ribbon fed through the
composer (in meters) and the amount of
PLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
veneer (in m²) that is potentially saved
yearly when correct attention is paid to
leading and trailing edge clipping. For
example, leading edge clip loss of 60
mm (2.3”) will result in a loss of almost
250,000 m² of veneer annually. Reduction
of the clip loss to 10 mm (0.4”) due to
proper thickness measurement will result
in a loss of less than 50,000 m². The gain
of 200,000m² of veneer can have a large
financial impact on a mill’s bottom line.
Graph 2 indicates the economical
benefits of proper servo-squaring. The
figures are based on a composer handling
4,000 lineal meters of veneer per 8-hour
shift. The veneer is mostly random size,
measuring 2,500 mm (98”) long, 700 mm
(28”) wide, and 1.5 mm (1/16”) thick. As
can be seen from the graph, a 10° misalignment will result in a bias clip loss equal to
20% of volume or around EUR 350,000
(approx. USD 435,000) per year.
Note: Price of finished plywood
given as EUR 500/m³ and veneer recovery
prior to layup is 73%.
that want to realize the maximum grading potential that only a high-intensity
camera grading system can provide or for
mills that want to detect and automatically divert veneer that has greater value
as face than as core.
Add up the savings and benefits
Plywood constructed from composed
core has higher market value and offers
wider market potential than simple 3-ply
sheathing products. For composing to
be economical, however, it must demonstrate high productivity without sacrificing quality or recovery. Raute’s veneer
composer upgrade with the Smart-Clip
function, servo-alignment and precise
thickness control can help you to achieve
these results. ●
Camera grading option
Mills have the option of equipping their
composing lines with a VDA camera
grader. This is worth considering by mills
17
Automatic ven
reaches record pace
BY JUSSI TOIVIO
18
neer patching
The new Raute automatic veneer patching line
installed at UPM’s Pellos 1 plywood mill in
Eastern Finland is running at a record level.
Installation of the 4-head line began on December
16, 2003 and, in only 35 days, it was operating at
137% capacity.
Mr. Jouko Pussi, Production Engineer, who
assumed responsibility on behalf of UPM
for the project stated that, “Based on our
calculations, UPM acquired the Patchman
automatic patching line to improve the
mill’s production efficiency and to lower
operating costs associated with manual
patching. The patching lines installed at the
other UPM plywood mills had proven to be
profitable investments, which encouraged
us to acquire a line as well.”
72,000 patches per shift
“The line replaced five manual patching
machines and patching capacity has more
than doubled. A particularly monotonous and demanding activity has been
automated, which has improved working
conditions in the mill. The line is under
the control of a single operator, who fills
the strip magazine, monitors the strip feed
and is responsible for the smooth operation of the line”, said Mr. Pussi.
PLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
“Sheet size varies between 2,500
x 2,500 mm and 1,600 x 3,300 mm (8’
x 8’ and 5’ x 10’). Veneer thickness varies between 1.5 and 2.6 mm (1/16” and
1/10”). Depending on the sheet size and the
number of patches per sheet, line capacity
is 9,000 patches/hour or around 72,000
patches in an 8-hour shift. The jigsaw
shaped patches have also proven to hold
well in the veneer”, added Mr. Pussi.
Start-up went as planned
“Prior to the line being taken into service, personnel from our mill who had
been chosen to make up the patching
group were trained at the UPM Jyväskylä
Plywood Mill on the automatic patching
line already in operation. Operators had
hands-on training in 1-week periods and
by the time installation began they were
highly motivated and already familiar
with the line. Personnel from Raute and
Mecano were responsible for the start-up
and fine-tuning and production started
without any particular difficulty”, said
the Pellos 1 Production Manager.
Production now easy to follow
Mr. Pussi was impressed with a number
of the Patchman’s special features.
“Managing the patching operation is
easier now that the Patchman is connected to the management information
and production management systems.
Production run programs can be designed
19
through the interface and their execution
is easy to follow. The system allows simulation runs with veneer data retrieved
from actual production. For example,
we are able to run different patching
scenarios in order to determine which
will maximize face veneer yield. It is also
possible to check sheet dimensions, sheet
squareness and other properties, which
improves sheet grading and specifies the
criteria for those veneers that are acceptable for layup. Such properties could not
be determined when the mill had only
manual grading.”
“Production management is also
easier because patching today is much
more efficient. Before, manual patching
of one stack of veneers could take a
whole shift whereas it now takes an hour.
Production is more flexible as we no
longer require buffer storage of patched
veneers. The bottleneck that existed with
the manual patching machines has been
eliminated.”
Further automation a certainty
Mr. Pussi saw considerable potential for
automatic veneer handling in the future.
“As the applications for automatic veneer
handling expand in the future, special
attention will be placed on all aspects
of quality. The quality of the loads will
be improved through the elimination of
cracks and trash that ends up in the loads.
Techniques for recoding and measuring veneer properties and defects will
improve the accuracy of veneer grading
and the quality of production. On automatic lines, the quality criteria will be met
with a high level of precision and uniform
veneer quality will be the result.”
20
Cost-efficient patching
and quality veneer
According to mill management, the main
criteria for justifying the investment were
improved efficiency and productivity,
together with cost savings. The size and
layout of the line allows veneers from the
Pellos 2 and 3 mills to be patched also.
Patching of the 8’ x 8’ veneers from Pellos
3 is the most efficient, as sheets of this size
normally require many patches. Sheets are
staged into the ready position while the
previous sheet is being patched, assuring
that the patching head is seldom idle.
“In the long run I would imagine
that the use of uniform quality face veneer
and thicker patched face veneers, which
comply with specified criteria, will benefit
the customer. The quality of the panel face
will be correct and in compliance with the
customer’s order. Patches won’t fall out
and product quality will be maintained
at a specified level from one order to the
next. However, it is not wise to produce
a product whose quality is clearly above
what the customer is requesting or what
he is prepared to pay for. Quality should be
based on acknowledged standards or on an
agreed-upon criteria. Patchman does that
for UPM”, concluded Mr. Pussi. ●
RS
PE
PA
G
TIN
NA
MI
LA
SO
EN
Win new customers
with overlaying
BY SEPPO LEPPÄNEN PHOTOS MINNA REINIKAINEN AND SEPPO LEPPÄNEN
Value adding to meet
customers’ needs
In recent years, the need for plywood producers globally to compete with alternative products has created the demand for
new applications. High-quality plywood
has been able to compete due to its superior properties and there is every reason
to believe that this situation will continue,
provided the plywood industry is able to
service the growing demands of the market with appropriate products.
However, panel overlaying is another way to add value to plywood and one that
will help plywood to face the competitive
challenges of the future. Overlaying technology has been proven as a way to add
value to panels through its many and varied
applications. It is a way for panel producers
to win new customers and markets by being
able to satisfy their ever-changing needs.
PLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
21
■ Overlaid plywood is used in trucks and trailers. Floors are made of wear- resistant overlaid
plywood featuring an anti-slip surface, whereas walls will have a satin finish that enables easy cleaning.
Overlaying application
to suit the end use
Overlaying improves the physical properties of basic panels. These may include
anti-slip properties, wear resistance,
moisture resistance and resistance to a
variety of ambient conditions. The broad
range of colors and textures available with
overlaying also makes overlaid panels a
desirable commodity.
In addition to traditional paint
and lacquer finishing, plywood can be
overlaid by pressing or gluing a thermoplastic self-adhering film onto its surface.
A typical overlaying material for plywood
is phenol-impregnated paper. Melamineimpregnated overlays are also used.
Phenol overlaid plywood for a
variety of end uses
Perhaps the most important application
for phenol-overlaid plywood is concrete
shuttering, where the wear resistance of
the overlay, combined with the inherent
strength of the panel and the ease with
which it is used to make concrete formwork are most apparent. Shuttering that
22
is well constructed, is thoroughly cleaned
after use and which has the appropriate
surface quality will withstand repeated
use and continue to render a smooth,
clean concrete surface. The strongest
shuttering plywood can be used up to
one hundred times and curved formwork
is relatively easy to make, given the flexibility of plywood.
Another, equally important use for
phenol-overlaid plywood can be found
in the transportation industry where the
strength of the basic panel, combined
with the moisture and weather resistance
provided by the overlay material, offers
a number of advantages. Wear-resistant
floors and walkways can be provided
with an anti-slip surface and walls can be
made resistant to mechanical wear and are
easier to keep clean when made of overlaid
material. The wide range of colors and
textures that are available provide variety
for the end-user.
Phenol-overlaid, textured plywood
is also used for making wear resistant,
anti-slip floors and walkways in industrial
buildings. Floors made in the 1970s using
wire mesh overlaid plywood are still intact,
after many years of substantial wear.
Plywood overlaid with colorful,
smooth overlays is also gaining ground as
wall elements in agricultural buildings. Its
moisture-resistance, durability and easy
care properties make it a natural choice.
Plywood for demanding
applications
Overlaid plywood has long been used in a
wide range of applications, such as highway signage. Signage panels are overlaid
with a material to which paint and other
adherents can be easily applied. The edges
are also sealed with paint for protection
against moisture.
An example of demanding applications for plywood are the interior walls of a
concert halls, where the natural beauty of
wood is combined with the acoustic properties of plywood in an excellent way.
Multi-daylight pressing technology
for manufacturing large batches
The most traditional overlaying technology has long been multi-daylight pressing,
PLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
which still has significance in the production of large batch production. Typical
products produced using multi-daylight
technology include smooth-faced concrete
shuttering and transportation panels and
panels incorporating wire mesh and other
textures used for flooring and walkways.
With multi-daylight technology, relatively
low pressing temperatures can be used,
which even allows for minor imperfections
in the quality of the substrate panel.
Textured surface using short-cycle
overlaying
A single-daylight short-cycle press is the
most suitable for overlaying small batch
lots when a variety of textured finishes are
produced using caul plates. In this case,
the frequency with which the caul plates
are changed out is important.
With the relatively high temperature of the short-cycle press, the requirements on the basic panel are significantly
greater than with multi-daylight technology. Caul plates can be used in either
application to create textured surface
finishes.
Raute’s long experience in the
plywood machinery business
Over the years, Raute has made great
strides in panel overlaying technology.
Numerous Raute multi-daylight overlaying lines are in operation in different
parts of the world, the earliest delivered
decades ago.
Short-cycle overlaying is a relatively new technology outside Finland, where
it has been used since the 1980s.
In addition to overlaying lines,
Raute supplies panel handling lines that
are used, for example, in edge trimming, edge sealing, patching and packaging, whether as stand-alone machines or
complete production lines. The control
systems provided with these value-adding
lines are provided to meet the needs of the
mill, either manual or automatic.
Raute also provides management
information systems that play an integral
role in modern production management
and planning. ●
23
Raute stacks up for
IP Wood
BY RICK MASSEY
International Paper Company, now IP Wood, is a leading producer
of Southern Yellow Pine (SYP) plywood. The company offers a wide
range of structural panel products from its five mills located throughout the Southern United States. Current production stands at over 1.6
billion square feet (1,42 million m³) of product each year and includes
composed core plywood, rated sheathing, industrial panels, sanded plywood, flooring, siding and a range of proprietary panel products.
■ Raute has close to one hundred dry veneer stackers operating in North America, many on Southern Yellow Pine.
24
IP Wood’s plywood mill in Corrigan,
Texas faced a number of challenges in
their dryer department that affected the
safety of their team members, as well
as dry end productivity and efficiency.
Faced with these challenges, management
decided to purchase two 12-bin Raute dry
veneer stackers in 2001.
Team member safety is of primary
concern to IP management. Dry veneer
sheets, moving at a constant speed and
consistent volume, create a demanding
and potentially injury-prone work environment. The high level of automation
provided by the stackers enabled virtually
hands-free operation and so reduced the
risk of operator injury considerably.
Then there was the issue of labor
and associated costs. Prior to installation
of the automatic dry stackers, each of
the two dry chains was manned by three
operators for a total of 6 operators per
shift. This number was reduced by half
to three operators, one of whom “floats”
between the two stackers, monitoring
the bins for skewed sheets or hang-ups.
Each of the other two operators has the
responsibility for monitoring the flow of
veneer out of the dryer and through the
grading stations.
The challenge associated with finding people to do a job that can be both
physically demanding and tedious was also
part of the purchase decision. Management
found itself having to constantly hire and
train new team members, which took time
away from their other duties.
Finally, with the need to constantly
train new team members came the potential for inconsistent grading, an issue that
has now been addressed to the satisfaction
of mill management.
Installation of the stackers took
place in the Fall of 2002 with each of the
two dryers; a 24-section and a 20-section,
receiving a Raute 12-bin dry veneer stacker.
Production Manager Sandy McCorvey,
an 18-year employee of the organization,
has played a major role in maintaining
the efficiency of the dry end. He talked
about the decision to buy from Raute and
the challenges of installing the stackers
without causing undue interruption to
dryer production.
“We were fortunate in having multibin Raute dry stackers operating at our
other mills and were guided by their consistent performance. It’s also our policy to
investigate equipment on the market that
is operating successfully and to understand
why. Add to this Raute’s reputation for
making a quality stacker that performs
to specification and we had our justification for purchasing from them”, said Mr.
McCorvey.
Raute presently has close to one
hundred dry veneer stackers operating in
North America, a large number of which
■ Parameter changes are
made at the touch screen monitor.
■ It took one shift to tie the two stackers into
the dryers, with minimal fine-tuning being needed.
■ Production Manager, Sandy McCorvey,
believes that proper planning led to a successful
dry stacker project - “It’s our policy to investigate
equipment on the market that is operating successfully and to understand why.”
PLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
4
25
are located in softwood plywood mills
in the Southern United States where the
principle raw material is Southern Yellow
Pine, a species noted for its waviness and
inconsistent moisture distribution. In all,
there are over twice that number operating
worldwide, in addition to several hundred
green veneer stackers.
The Corrigan Production Manager
spoke highly of the team that was assembled ■ A team member monitors both stackers, correcting skewed
from within the mill to oversee the project. sheets and removing veneer that may have become hung up.
“We assembled a team comprised of operational and maintenance team members
who, between them, were responsible for service people did an excellent job. All significantly to the successful operation
overseeing installation, start-up and train- told, it took only one shift to tie the two of the stackers. “Internally, we have come
ing”, said Mr. McCorvey.
stackers into the dryers and the amount of up with ideas and maintenance procedures
He went on to explain that team fine-tuning needed was minimal.”
that have made the stackers perform just
members received training at other
He went on to add that everyone that little bit better. As you can imagine,
IP Wood mills that were operating Raute involved in the installation displayed a very with summer temperatures in the mill
dry veneer stackers. “With the hands-on professional and flexible attitude. “When often running over 100 degrees F., and
training provided by the other IP mills last minute changes needed to be made, humidity upwards of 90 percent, we have
and the training material provided by the crew was able to take care of things our challenges with equipment.”
Raute, our team members were more than without any complaint or difficulty”, said
Finally, McCorvey did offer some
ready to go once the equipment became Mr. McCorvey.
words of advice for maintenance people
operational”, he added.
Since start-up, the stackers have who want their stackers to run efficiently.
McCorvey was equally complimen- performed well, according to McCorvey. “Put in place a preventative maintenance
tary when speaking of the installation “They have lived up to IP’s expectations and program that includes proper attention
crews. “We had a very tight window of have demonstrated their ability to properly to lubrication and air cylinders and make
time during which we had to make the
stack dry veneer.”
sure your stacker is operating on dry air.
stackers operational. Both our electrical
McCorvey did, however, stress that Do these things and your stacker will perand mechanical contractors and the Raute the IP team members have contributed form as it should.” ●
■ Raute dry veneer stackers have a
reputation for producing square loads on a
consistent basis.
26
New stacker controls
raise green end and dryer productivity
■ Raute has acquired a solid reputation for the quality of its green and dry
veneer stacking technology, both for the
efficiency of the stacking process and the
high standards of its workmanship.
PLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
Canfor is the largest producer of softwood
lumber and one of the largest producers of
northern softwood kraft pulp in Canada.
All told, the company operates 34 production facilities in British Columbia, Alberta
and Quebec. On the panel side, Canfor
operates plywood mills in Prince George
and Fort Nelson, B.C., the combined annual
production of which is 460 million square
feet of product annually (400,000 m³). The
company’s PolarBoard OSB mill, also located in Fort Nelson, has an annual capacity
of 510 million square feet (450,000 m³).
Canfor is currently involved in a joint-venture project with Louisiana-Pacific, which
will result in the construction of a new OSB
mill in Fort St. John, B.C., annual production of which is expected to be 820 million
square feet (725,000 m³).
When management of Canfor
approached Raute about problems with the
performance of the green veneer stacker
controls in their plywood mill, two important issues stood out - inconsistent moisture
sorting and excessive redry, the results of
which were lost green end production and
inefficient drying.
Located in Prince George in north
central British Columbia, Canada, the
Canfor mill produces softwood plywood
from spruce, pine and fir. Proper moisture
control is especially important to the mill
since there are wide variations in moisture
content of the species they process.
According to Canfor management,
the mill had spent considerable time working
with their vendor trying to solve the problem
before calling on Raute’s electrical controls
people. After careful analysis of the situation
it was determined that the fault lay with the
moisture sort controls, which were providing
inadequate data for proper moisture sorting
in the green stackers. Periodic tune-ups to
the system tended to alleviate the problem
but provided only a temporary fix. Raute’s
suggestion was to replace the existing
stacker controls and to add a sophisticated
moisture classification program to accurately identify moisture in each sheet. This
approach, it was determined, would greatly
improve moisture classification over simple
sheet moisture averaging.
In the first quarter of 2004, the mill
made the decision to have Raute replace
the existing controls. Each of the two stackers, a two-bin and a four-bin unit, received
Control Logix processors for knock-off control and moisture sorting and Ethernet connections for MIS and remote troubleshooting. PLC racks and terminals were inserted
into the existing cabinetry with minimal
downtime and disruption to production. In
addition, some existing components in the
bins were replaced to improve performance. A new push-button console was also
installed to enable easier access, as well as a
touch-screen monitor complete with menu
set-up and troubleshooting screens.
Raute’s service technicians also took
responsibility for servicing the existing moisture sensors and provided training for the
mill’s operators, production management
and maintenance staff.
In order to check the results of the
green stacker controls upgrade, moisture
sort testing was carried out prior to and
after the upgrades had been completed.
Testing consisted of measuring and weighing a sampling of sheets and checking the
moisture targets set by the mill. The data
collected provided references for green end
operations and for future benchmarking.
Following the upgrade, Canfor management reported significant improvements
in the operation of the two green stackers.
In all, redry, overdry and underdry targets
were met and dryer production improved,
due to more accurate and consistent moisture sorting. The redry percentage, which
had been as high as 23 per cent, dropped
significantly. Green end production rose
overall by almost 12 percent, exceeding the
target by over 8 percent. Mill management
reported that payback for the upgrade
project was achieved in less than two
months. Improvements in the squareness
and quality of the green veneer loads were
also achieved, which led to improvements in
veneer handling further along the process,
particularly at the infeeds and outfeeds of
the dryers.
It was especially satisfying to Raute’s
service technicians that the upgrades were
completed and both stackers were back on
line and in full production within 24 hours
of the work being started.
To date, Raute has carried out several controls upgrades on both green and dry
veneer stackers with positive results, helping
mills to achieve higher speed, better accuracy, tighter moisture control and improved
grading results. ●
27
Monzón’s poplar plywood
business enjoys fair winds
28
Raute’s RWS-Engineering division boosts performance of Spanish poplar plywood producer
with consulting services and reconditioned
machinery.
Industrias Monzón, located in Ateca, in
the northern Spanish province of Zaragoza,
is a privately-owned company started by the
father of Fernando and Alfredo Martinez Sanz
in 1962. The company that began by producing planed wooden slats for fruit boxes started
exporting case components in 1970 and, in
1989 they produced their first poplar plywood
panels. Production continued to grow and
the mill emerged as a true industrial venture
in the early 1990s. Today, Managing Director
Fernando Martinez Sanz manages Monzón,
together with his brother Alfredo.
BY MERJA HAKALA
■ The Industrias Monzón
plywood mill is located in Ateca in
the Zaragoza province.
PLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
Certified products for
export use local wood
Monzón started up its wood procurement
business in 1997. Today, the company works
together with the local government to promote the business of growing trees and the
cultivation of poplar in the region.
The main product made by Monzón
is 4’x4’ poplar plywood available in a variety of grades and thicknesses. Recently,
however, production of 4’x8’ plywood is on
the rise. Raw material comes from within a
200 km radius of the mill. Annual production stands at around 15,000 m³.
Wood by-products, such as sawdust
and chips, are used to fuel the boiler, with
excess material being sold for the production of particleboard. Cores peeled to a
diameter of 78 mm are used in the manufacture of pallets.
All plywood sold by Monzón carries a label certifying that it is made of
100% recyclable material and meets the
E1 standard, making it suitable for applications in the food industry.
■ Monzón harvests poplar within a 200-km radius of the mill.
29
■ Cooperation between Raute and Industrias Monzón began following a visit by
Raute’s representative in Spain, Mr. Hannu Vainio (right). Hannu and Alfredo Martinez Sanz
are seen here inspecting one of Monzón’s products.
Presently, Industrias Monzón
employs 50 persons and exports to eg.
France, the Netherlands, Great Britain
and Morocco.
Development plan results in a
major leap forward
On the basis of a development plan put
together by Raute’s RWS-Engineering division, the Monzón mill was able to make
a major leap forward in 2001. The seeds
for the plan were planted during a visit
by Raute’s representative in Spain, Mr.
Hannu Vainio, to the mill. Mr. Vainio
saw that Monzón would benefit by having
a structured business development plan and
arranged a trip for Fernando and Alfredo
Martinez Sanz to Finland where they had
the opportunity to acquaint themselves
with Raute.
For the Monzón owners, the need to
have a solid plan for moving forward in their
business became evident following discussions with Raute’s plywood specialists. The
basis for proceeding with the project was a
poplar plywood market study provided by
RWS-Engineering. Monzón management
saw the benefits in dealing with RWS-
Engineering and invited them to proceed
with a technical development plan and a
study of the local business conditions.
Monzón. The main areas covered in the
report included:
●
Technical development plan
promotes change
Spain has numerous poplar plywood producers. In the case of Monzón, production
had been concentrated on making components for fruit boxes, which involved
making small, mainly thin panels that
were cut into suitable dimensions. This
traditional product has for some time
been under pressure from producers
operating in countries that enjoy lower
production costs. The technical development plan produced by RWS-Engineering
stressed the need for a new type of product
and new markets.
Scope of the RWS-Engineering
business plan
This market study and development plan
focused on three main issues: recent
developments in the European plywood
business, the market position of poplar
plywood, and presentation of a technical
concept for the development of Industrias
●
●
●
wood supply situation generally
in the plywood industry with
emphasis on the supply of poplar
development of plywood markets
over the preceding two decades
with emphasis on poplar plywood
in Europe
formulation of a plan for the
future development of Monzón’s
poplar plywood business
process calculations and technical
specifications
The technical plan specified the
necessary performance parameters of the
existing machinery as well as cost estimations and labour requirement by shift for
each machine. RWS-Engineering offered
several suggestions for the layout of the
machinery and equipment in the plant.
Although the plan did not include
feasibility calculations, it did provide
investment estimates covering the purchase and installation of additional equipment.
■ The founder and his wife still reside
nearby the mill.
30
Poplar plywood in Europe
The production of poplar (and aspen) plywood in Europe is approx. 900,000 m³/a,
representing some 15% of the total plywood
production. The biggest European poplar
plywood producers are Italy (450,000 m³/a)
and Spain (245,000 m³/a). The major end-uses
of poplar plywood in Europe are furniture,
packing (fruit boxes) and caravans.
■ Industrias Monzón’s main product is poplar
plywood in a variety of grades and thicknesses. The
mill’s Technical Director, Mr. Antonio Heredia, is seen
together with Director Alfredo Martinez Sanz.
Step-by-step approach
The first visible signs of cooperation
between Monzón and Raute, even
before the business development plan
was assembled, was the purchase by
Monzón of a reconditioned Raute XY
charger, which was installed ahead of
their Spanish-made lathe. Installation
of the charger resulted in a significant
rise in recovery.
Now in the fourth year of the development plan, Industrias Monzón continues with their step-by-step approach. They
have continued to upgrade the peeling line,
adding a reconditioned Raute RCH rotary
veneer clipper complete with moisture
grading and a 3-bin stacker modified to
handle thin veneer.A scarf-jointing line and
15-opening hot press, both reconditioned
and supplied by RWS-Engineering, were
installed in 2003. The press plays a dual
role, being used to press poplar plywood
and for overlaying. These new production
lines have enabled the mill to expand their
business into the lucrative 4’x8’ panel markets. A number of technical specialists from
Raute and RWS-Engineering have been
training Monzón personnel in the operation of the machinery and in production
management.
The future
The management of Industrias Monzón
have stated their satisfaction with the
cooperation and professional assistance
they have received from both RWSEngineering and Raute and have made it
known that they are open to new product
ideas. Their aim is to continue to increase
production and further refine the quality of their production. According to
Alfredo Martinez Sanz , “The management of Monzón have come to trust
and rely on the know-how provided by
RWS-Engineering and Raute and further
cooperation is planned.” ●
Poplar & Aspen plywood production in Europe
Total production approx. 900,000 m³/a
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Poplar plywood end-uses in Italy
Production approx. 450,000 m³/a
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Poplar plywood end-uses in Spain
Production approx. 245,000 m³/a
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■ RWS-Engineering supplied a reconditioned 15-opening
plywood press, which doubles as
an overlaying line.
PLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
31
On 28th May, 2004 Raute Group Asia
Pte Ltd celebrated its 20th year of
operation in Singapore. A party was
held to thank the many suppliers,
business partners and Singaporebased customers who have given their
help and support over the past two
decades. Guest speaker was Finland’s
ambassador to Singapore, H.E. Mr. Kim
Luotonen, who gave a presentation
concerning Finland’s trade in Asia.
Raute celebrates
20 years
in Singapore
BY DORIS DOH
■ Mr Goh, Indo Sumatera,
Ms Lina Farriek and friend from
Grenzebach Bsh Asia, Max Theobald
and Juergen Schaetzlein, Leitz Tooling.
32
■ Mr. Jukka Siiriäinen,
President of Raute Group Asia
(left) spoke on the history of Raute
in Singapore. The Ambassador of
Finland, H.E. Mr. Kim Luotonen
held a speech on Finland’s trade in
Asia.
Mr. Jukka Siiriäinen, President of Raute
Group Asia spoke on the history of Raute
in Singapore. In summary:
“In June, 1984 Raute was granted
a license to undertake business activities
under the direction of Mr. Fred Choo.
Two years later the office relocated to
Jakarta under the direction of Mr. Kari
Sundman. After 4 years in Jakarta it was
decided that the office would return to
Singapore because of that nation’s superior infrastructure and better geographical
location. Mr. Timo Lampila took charge
of the Singapore office in July 1990. He
hired Ms. Doris Doh as assistant to the
President, a position she continues to
hold to this day. The Customer Service
Department was added to the Singapore
operation in 1993 to support the growing
business and, in 1994, Raute demonstrated
its commitment to the Asian market by
eliminating the Representative Office status and becoming a fully-fledged Private
Limited Company. That same year, Raute
reactivated the Representative Office in
Jakarta. In 1998 there was a change in
leadership of the Singapore office when
Mr. Lampila handed over the reins to Mr.
Jukka Siiriäinen and returned to Finland.
A year later, a Representative Office was
opened in Beijing. To better reflect the
role of the Singapore office, its title was
officially changed to Raute Group Asia Pte
Ltd in 2000.”
Once the formalities had been completed, a toast was proposed to the future
of Raute Singapore and the festivities got
under way with a bang from a confettifilled canon. All through the evening guests
were treated to caricature drawings and
Chinese calligraphy, while background
music provided an unimposing ambiance. The highlight of the evening, all
agreed, was provided by “William”, an
accomplished entertainer from the United
States, who entertained the guests with his
broad selection of songs and jokes. The
good food, refreshing “adult beverages”
and good time had by all the guests was
a fitting tribute to the management and
staff of Raute’s Singapore office who have
worked so diligently to establish the company’s presence in Asia. ●
PLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
■ Antero Velling with
Jarmo Orpana of Valon Kone.
■ Caricature station.
33
Customer contributes to the innovation behind
the new design of the die cutter used in the
Patchman automatic veneer patching machine
■ The “Butterfly” patch.
Cooperation
BY ERKKI KAURANEN
“In the course of the die cutter project,
the importance of co-operation between
the technology supplier and the customer
in reaching a common goal was apparent.
The cooperation, feedback and communication have been excellent in all areas”
- Mr. Erkki Kauranen of Mecano Group,
manufacturer of the Patchman.
Mecano takes a multi-phased
approach to die cutter
development
Prior to beginning this project, Mecano’s
experience and success in patching thin
veneer (1.5 mm or 1/16 inch) had been
limited mainly to birch. The challenges
involved in patching softwood veneer had
not yet come to light. Therefore, when the
opportunity to patch production volumes
of thin softwood veneer was made available at the UPM-Kymmene Jyväskylä
Plywood Mill, Mecano was pleased to take
up the challenge.
Initial trials involved patching birch
veneer using a “Butterfly” shaped die cutter, which was used mainly for patching
thin veneer.
It soon became apparent, however,
that the patches would not adhere well to
the softwood. Work began on the design
of a different die cutter as soon as the first
signs of this defect were detected. At the
same time, the method by which the defect
removal pin is connected was changed in
34
order to accommodate a die cutter with a
smaller circumference.
The new “Jigsaw” design type, was
developed to improve patch retention. The
number of pin housing holes in the new
die cutter was also increased and, due to
its shape, the new patch was called “Small
Jigsaw”.
Testing showed that the new design
improved patch retention considerably.
However, a new challenge arose: the presence of slivers that collected beneath the
patch. The size of the slivers varied from
about the size of a match to strips approximately 5 mm in width. Wide slivers on the
veneer sheets created problems with glue
application and caused telegraphing in
overlaid panels.
A multi-phased approach was taken
to identifying and overcoming the problems.
In Phase one, the sidewalls of the
die cutter were made thinner, causing
the cutout patch to fit more securely in
the cutter and preventing the edges from
splitting. The sidewalls could not, however,
be made too thin or the durability of the
cutter would have been compromised.
Also, to ensure that the defect fitted more
smoothly into the die cutter, the cutting
edge angle was altered. These measures
improved the situation, but did not solve
the problem entirely.
In Phase two, the cutting depth of
the die cutter was increased. This improved
the process of removing the defect and
decreased the amount of slivers. Increasing
the cutting depth did, however, present
another challenge: increased patch anvil
wear.
Phase three involved finding a way
to improve the durability of the anvil. The
solution lay in controlling the cutter head
movement so that the it never hit the same
spot on the patching anvil twice. As a result,
there was less anvil wear.
Phase four involved finding a
solution to the problem of the slivers.
After experimenting with various kinds
of brushes and air knives, it was the
customer who came up with a workable
solution: provide an air channel inside the
die cutter that would direct a jet of air to
dislodge the slivers.
This method proved so effective
that slivers ceased to be a problem and
the resulting quality from the line fully
met the customer’s expectations for veneer
quality.
Consequently, all die cutters now
incorporate an air channel that can be
enabled, if necessary. All remaining die
cutters in use at the UPM-Kymmene
Jyväskylä Plywood Mill are currently being
retrofitted to include the air channel and
this feature will be added to two additional
patching heads.
The man behind this innovation
was Mr. Kari Turpeinen from the UPM-
■ The “Small Jigsaw” patch.
improves quality
Kymmene Jyväskylä Plywood Mill. In
recognition, he was awarded a Raute Client
Initiative Certificate, together with a token
of appreciation.
Ideas derive from the desire to
produce high quality
Erkki Kauranen praised the cooperation
he received from the customer during this
project. “The desire to produce high quality products as efficiently as possible gives
people the necessary drive to face development challenges. It enables them to
look for solutions and reach their desired
goals. Thanks to their skilled staff, the
UPM-Kymmene Jyväskylä Plywood Mill
is the right place for testing new ideas and
products also in the future.” ●
■ At the awards ceremony were, from the left: Juhani Lappeteläinen, Maintenance
Manager and Juhani Tenhunen, Production Engineer, UPM-Kymmene; Olli Hakanen,
Project Manager, Raute; Kari Turpeinen, Millwright, UPM-Kymmene; Tapani Kiiski,
President and CEO, Raute; Ilpo Pasanen, Supervisor and Keijo Nurkka, Electrical Designer,
UPM-Kymmene; and Sauli Salmela, Area Sales Manager, Raute.
PLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
More information:
Mecano Group Oy
Erkki Kauranen
Syväojankatu 8
87700 Kajaani, FINLAND
Tel: +358-8-8776 700
Fax: +358-8-6121 982
35
Trade shows
WoodTech showcases new products in
■ The new VDA Color offers the latest in dry veneer camera grading to an industry that
has come to rely on the accuracy and repeatable performance of camera scanning technology.
Raute’s decision to
exhibit at the Wood
Technology Clinic
& Show in Portland,
Oregon on even
years only appears to
have paid dividends,
judging by the high
level of interest shown
by visitors to our
booth at this year’s
event.
36
The highlight of our stand was, perhaps,
our latest innovation in block optimization
- the Smart-Scan XY+, a term that aptly
describes the technology behind this latest innovation from Raute. The data made
available by Smart-Scan enables automatic
carriage positioning by using laser curtain
scanning to capture every defect, especially
protruding knots, on the surface of the
block. The 8,000 plus data points that
are generated per block provide a true 3D
image to ensure precise scanning.
Since the new Smart-Scan XY+ was
introduced to the market in early 2004, six
systems have been sold.
Alongside Smart-Scan, the new
combination VDA Color veneer grader and
DMA moisture analyzer commanded a lot
of attention. This is the first camera-based
veneer grading system to recognize color
variations on veneer and so represents the
latest generation in scanning technology.
The DMA’s precise moisture analysis provides accurate and reliable dryer
control, as well as average and peak mois-
ture levels and a detailed moisture map
of each sheet of veneer. DMA also enables
moisture limits to be set for different areas
of the veneer sheet. With its unique moisture mapping capabilities and moisture
grading analysis, DMA provides precise
dry end control and monitoring. When
combined with the visual grading accuracy
of the VDA grade scanner, the result is a
powerful dry end management tool.
Also displayed in the booth was a
sample of veneer wrapped using the Cross
Wrap 3D packaging system. This patented
technology from Cross Wrap of Finland
uses patented technology to seal all edges
and corners of the package, making the contents resistant to cold, heat and moisture.
The packaging material is PE-film,
a recyclable plastic that can be disposed
of in landfills or incinerated. Packages
are airtight and do not require additional
banding or corner supports.
3-D wrapping ensures that packages
remains intact during transportation and
storage. They may even be slit and product
and fairs
North America
■ The Beijing Exhibition Centre.
■ [left] This specially-constructed
working model of the new Smart-Scan XY+
commanded a lot of attention from visitors
to Raute’s booth the 2004 Wood Technology
Show in Portland, Oregon.
removed without compromising the stability of the contents. Packages remain intact,
even when rolled.
The lower labor and material
requirements offered by Cross Wrap may
reduce packaging costs by as much as 60%
over competing systems.
Other products of particular interest were the new random veneer stacker,
the new random selector for handling
green veneer at high speed after the clipper
and the numerous equipment upgrades
and modernizations that are on offer.
AusTimber 2004, Albury, Australia
AusTimber is held every four years in the
town of Albury, New South Wales, about
500 kms southwest of Sydney. Although
primarily a venue for forestry equipment,
it attracts a broad audience that includes
sawmillers and panel producers, among
others.
As it has done previously at the
Albury show and its counterpart in
Rotorua, New Zealand, Raute chose to parPLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
ticipate as part of the Canadian Pavilion,
using the resources of Raute Wood Ltd.,
Raute’s manufacturing facility in New
Westminster, British Columbia.
All told, some twenty Canadian
companies were represented, some of
which have been doing business in the
region for a number of years, and others
that were hoping to learn more about what
is becoming an increasingly important
market for forestry and wood products
manufacturing technology.
Raute can claim to have considerable experience in the Australasian market.
To date we have installed plywood and LVL
equipment at a number of mills in New
Zealand and Australia, our most recent
project being the Wesbeam plywood and
LVL mill in Perth, Western Australia.
Chinawood 2004, Beijing, China
Chinawood 2004 took place this past
March 7 - 10 in Beijing, China. As this
was the first time this event has been
held, anticipation among the exhibitors
was high as to what the level of participation would be. Although attendance was
somewhat disappointing, endorsement by
Eumabois, the European Federation of
Woodworking Machinery Manufacturers,
should provide support for future events.
Raute was represented at Chinawood by
Shengfu Wu and Wendy Lee (pictured)
from our Beijing office, Patrick Wong
from Raute Group Asia in Singapore,
Merja Hakala (pictured) and Matti Aho
from Raute Finland and Olli Havo from
RWS-Engineering, Finland. ●
37
appointments at raute wood
Tapani Kiiski
Timo Kangas
Juha-Pekka
Salimäki
Kimmo Ahonen
Vladimir Shvets
Arto Välimaa
Dave Ward
Glen Keown
Mr. Tapani Kiiski
was recently named as
President & CEO of Raute
Oyj. Prior to taking up
his new appointment, Mr.
Kiiski held senior positions
in Sales & Marketing and
Technology Management
within Raute.
Mr. Timo Kangas
has been appointed
General Manager, Services.
Mr. Kangas joined Raute
from the Finnish company
YIT where he was responsible for providing a range
of upkeep services to companies within the property
and construction sectors.
Mr. Juha-Pekka
Salimäki has been appointed Area Sales Manager
covering a number of
European countries,
including France, Spain,
Portugal, Germany, Austria,
Greece and Turkey. Mr.
Salimäki has previously
held sales and service positions within Raute.
Mr. Kimmo Ahonen
has been named Area Sales
Manager, Russia Group,
and Mr. Vladimir Shvets
has been named Sales
Representative. Both appointments will further strengthen
Raute’s position in the growing Russian market.
Mr. Arto Välimaa
has been named Sales
Manager, Services. He will
be responsible for developing the spare parts business,
modernization projects and
service contracts with special focus on Russia and the
Baltic countries.
Mr. Dave Ward and
Mr. Glen Keown have been
named as Territory Service
Representatives for Western
Canada and the Pacific
Northwest region of the
United States respectively.
They join Raute’s existing
TSR team of George Stoma
and Russ Gordon, who
have responsibility for other
regions within the United
States.
HARDWOOD PLYWOOD BUSINESS UP TO 2015
RWS-Engineering Oy is an international
engineering and consulting company
specialized in the wood based panel
industry. RWS-Engineering Oy belongs
to the RAUTE WOOD organisation. We
have released a new report covering the
present and future opportunities of the
hardwood plywood business worldwide.
The report concentrates especially on
the fluctuating business environment
of the hardwood plywood producers
considering future changes in the raw
material supply and plywood markets.
The report describes the development in
all main producer and consumer areas
in the world. Some highlights of this
report are:
38
●
●
●
●
●
●
Market and price development
of hardwood plywood
Global hardwood log resources
and their trends
End uses of hardwood plywood
and substituting wood-based panels
Cost comparison of main
hardwood plywood producers
Key success factors and main
strategies in the hardwood
plywood business
Market prospects and trends
in the hardwood plywood
business up to 2015
The report includes 112 pages with about 80
easily readable colour figures and tables.
This report will give you an excellent
view of the hardwood plywood business
and help you in your business strategy. The
price of one copy is EUR 1500 only. The
price of an additional copy is EUR 600.
Enclosed please find an order form
for this report. The study will be sent to
you on receipt of your payment. Do not
hesitate to contact us concerning this study
or any other services of interest to you.
Postal address:
RWS-Engineering Oy
Phone: +358-3-82961
Fax: +358-3-762 2378
Tuhkamäentie 2
FIN-15540 Villähde, FINLAND
E-mail: [email protected]
FINLAND
ITALY
USA
CHINA
Raute Oyj
Raute Wood
Rautetie 2, P.O.Box 69
FIN-15551 Nastola
Tel: +358-3-82911
Fax: +358-3-829 3511
[email protected]
Intercomer S.R.L.
Via Paracelso 14
20041 Agrate Brianza
Milan
Tel: +39-039-605 8057
Fax: +39-039-605 6462
[email protected]
Renzo Orbolato
Raute Wood Inc.
50 Commercial Loop Way,
Suite A
Rossville, TN 38066
Tel : +1-901-853 7290
Fax: +1-901-853 4765
[email protected]
Raute Wood
Customer service
P.O.Box 69
FIN-15551 Nastola
Tel: +358-3-829 11
24 h: +358-3-829 3600
Fax: +358-3-829 3345
[email protected]
TURKEY
Raute Wood Beijing Rep.
Office
Office 969 Poly Plaza
14 Dongzhimen Nandajie
Dongcheng District
Beijing 100027
Tel: +86-10-650 116 98
Fax: +86-10-650 117 98
[email protected]
Wendy Lee
Raute Wood Inc
9940 S.W. Buckskin Terrace
Beaverton, OR 97008, USA
YENTÜR Orman Ürunleri ve Tel: +1-503-530-5102
Ins. San. Tic. Ltd. Sti.
Fax: +1-503-530-5393
General Nekmi Öktem Sok. [email protected]
4/1, Erenköy
Arne Nordstrand
34738 Istanbul, TURKEY
Howard Westhora
Tel: +90-216-368 3573
Fax: +90-216-368 4756
CHILE
[email protected]
RWS-Engineering Oy
Raute Wood Santiago
Mehmet Yentür
Tuhkamäentie 2
Hernando de Aguirre 162
SLOVAK REPUBLIC
FIN-15540 Villähde
Office 704
Providencia, Santiago
Tel: +358-3-829 61
Association of Wood
Tel: 56-2-233 4812
Fax: +358-3-762 2378
Processing Manufacturers
Fax: 56-2-233 4748
[email protected] T.G. Masaryka 24
[email protected]
96053 Zwolen
Raute Jyväskylä
Timo Reinikainen
Tel: +421-45 5330 278
Hakkutie 3
Fax: +421-45 5330 278
ARGENTINA
FIN-40320 Jyväskylä
[email protected]
Tel: +358-14-445 4400
Roman Reh
Oscar E. Bruschstein
Fax: +358-14-445 4429
Demaria 336
RUSSIA
[email protected]
(1846) Adrogué
Raute Oyj
Tel: 54-11-4294 1488
Mecano Group Oy
Arhangelsky per., 1
Fax: 54-11- 4293 5997
Syväojankatu 8
101934 Moscow
[email protected]
FIN-87700 Kajaani
Tel: +7-095-207 8794
BRAZIL
Tel: +358-8-877 6700
Fax: +7-095-207 8794
Fax: +358-8-612 1982
Irina Shadrina
Indumec Indústria Mecánica
firstname.lastname@ mecanoLtda
“FPT” Co Ltd
group.com
Novorossiyskaya Street 1/107, Rue General Potiguara 1115
FRANCE
Finnso Bois S.A.R.L.
18, quai Louis Blériot
F-75016 Paris
Tel: +33-1-452 773 40
Fax:+33-1-452 773 41
[email protected]
Christian Lallia
SPAIN
Adecor Consulting S.L.
Avda de la Vega 8 -2- 2B
28100 Alcobendas, Madrid,
SPAIN
Tel: +34-91-662 2923
Fax: +34-91-662 2931
[email protected]
Hannu Vainio
POLAND
Kauko Metex Ltd.
Sloneczna 35
00-789 Warsaw
Tel: +48-22-330 1200
Fax: +48-22-330 1212
[email protected]
Artur Kozohorski
PLYVISIONS RAUTE CUSTOMER MAGAZINE 1/2004
room 63
194021 St. Petersburg, RUSSIA
Tel: +7-812 9738471
[email protected]
Vladimir Shvets
CANADA
Raute Wood Ltd
5 Capilano Way
New Westminster, B.C.
CANADA V3L 5G3
Tel: +1-604-524-6611
Fax: +1-604-521-4035
[email protected]
Customer Service
USA and Canada
Spare parts
Toll free: 1-877-297-2787
Fax: 1-866-615-1379
24-hour emergency pager:
1-604-640-8311
[email protected]
Equipment Service
Toll free: 1-877-728-8373
Fax: 1-866-517-6811
24-hour emergency pager:
1-604-667-0482
[email protected]
Fazendinha, PR Curitiba
81050-500
Tel: +55-41-347 2412
Fax: +55-41-347 4545
[email protected]
Eduardo Koller
Stefano Koller
MEXICO
Equipos Interpulp S.A. DE
C.V.
Eugenio Sue 35,
Col.Chapultepec Polanco
CP 11560 Mexico DF
Tel: +52-5-5279 0540
Fax : +52-5-281 0689
[email protected]
Rolando Palomares Hilton
~iga
Gonzalo Idarraga Zun
INDONESIA
Raute Wood Indonesia Rep.
Office
Jl. Kelapa Tiga/Joe No. 75
Jagakarsa, Jakarta 12620
Tel: +62-21-788 86461
Fax: +62-21-788 89867
KOREA
J & C Corporation
RM 922 You One Golden
Tower
474-80 Bujeon 1 Dong,
Pusanjin-Gu
Pusan
Tel: +82-51-803 6586
Fax: +82-51-803 6588
[email protected]
J.J.Je, President
PHILIPPINES
Nicky Yao
12 Katherine St.
Parkway Village
Balintawak, Quezon City
Metro Manila
Tel: +63-2-414 5747
Fax: +63-2-362 2320
[email protected]
THAILAND
S.W.D. Machinery Co. Ltd
35/172 Moo 4 Soi Yuvijit,
Banga-Trad Rd km 1
Bagna, Bangkok 10260
Tel: +66-2-399 2113
Fax: +66-2-399 2119
[email protected]
Santhiti Siricheowsakul
SINGAPORE
Raute Group Asia Pte Ltd
35 Jalan Pemimpin # 06-02
Wedge Mount Industrial
Building
SINGAPORE 577 176
Tel: +65-6250 4322
Fax: +65-6250 5322
[email protected]
39
“Your partner in
performance”
You have a need to…
• Increase recovery
• Improve quality
• Raise capacity
• Be more profitable
We have the technology, people
and experience to make it happen.
www.raute.com