seeing both sides - usnr

INSIDERMillwide

THE MAGAZINE FROM USNR | ISSUE 5 - 2011

SEEING BOTH SIDESREDESIGNING THE PROCESS

USNR SORTS IT OUT FOR YOU

Allegheny Wood Products puts dual-side LASAR scanning to the test

Louisiana Hardwoods takes its edger line to a whole new level

USNR outlines sorting features designed to make the job easy

While markets fluctuate our customers continue to take advantage of the

oppor tunities at hand by improving the efficiency and effectiveness of their

operations, with outstanding results.

Those in the hardwood industry are experiencing similar

difficulties as processors of sof twood products. This issue

features stories of two of USNR’s hardwood customers.

Despite a bear market they are forging ahead to improve their

lot with new technology and new processes.

USNR has developed the MillExper t software platform with

many features that par ticularly address the needs of hardwood

producers. This issue expands on some of those features.

You’ll also find answers to many issues you may encounter

with sor ting your products. USNR has been in the business of

designing sor ting systems for a multitude of decades. Utilizing

USNR designs, customers all over the world are finding ways to

resolve problems surrounding an increasing variety of products.

Customers with veneer drying systems are also improving

on efficiency by insulating their dryer floors. This is a cost-

effective improvement that will save you money.

Whatever the processing issue that is causing your operation to miss out on

oppor tunities, let us help you find a solution that fits your needs and budget.

Sincerely,

Colleen Schonheiter

Editor

Opportunities at hand

ISSUE 5 - 2011

SubScriptiOnS

Tel.: 250.833.3028

[email protected]

EditOr

Colleen Schonheiter

[email protected]

cOntributinG EditOr

Sonia Perrine

[email protected]

uSnr partS & SErvicE

7/24 Service: 800.BUY.USNR

Tel.: 360.225.8267

Fax: 360.225.7146

Mon. - Fri. 5:00 am - 5:00 pm PDT

www.usnr.com

uSnr LOcatiOnS

© 2011, U.S. Natural Resources, Inc.

All rights reserved.

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Addresses to: USNR c/o Colleen Schonheiter,

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INSIDERMillwide

ISSUE 5 - 2011 | Millwide INSIDER 3

When is it the right time to update technology? The

abiding strategy for Allegheny Wood Products (AWP)

is to continually build on its strength for ferreting out

sound opportunities to increase efficiency. Earlier

this year its Kingwood, West Virginia sawmill updated

the optimization systems on its two headrig carriages

with the combination of LASAR scanning and the

MillExpert optimization platform. Concurrently,

the trimmer optimizer was also modernized with

MillExpert and new computer hardware while retaining

its existing scanning system.

This green hardwood operation processes poplar,

red oak, and hard and soft maple into boards of

4/4, 5/4, 6/4, 8/4, cross ties and some switch

ties. Products are sold globally for the manufacture

of furniture, cabinetry, millwork, moulding, and

more. Some of the production is sold green, while

the remainder is shipped to its sister company,

Allegheny Wood Products International at Hazelton,

West Virginia for drying. At Kingwood, its annual

capacity for a single shift averages between 22-24

mmbf; typically it runs two shifts with average

capacity exceeding 40 mmbf.

The Kingwood mill features primarily USNR

equipment including its two carriage optimization

systems, gang saw, optimized edger and trimmer,

and its sorter/stacker system. When the decision was

made to update the carriage and trimmer technology,

all major vendors were evaluated. Mike Frantz, AWP’s

IT director, commented that USNR was the vendor

of choice because it had the best products for the

application. The precursor to the LASAR/MillExpert

system on the carriages was USNR’s ScanMax system

that was new to the mill around the year 2000. With

11 years in operation Mike knew there was better

technology available to stay ahead of the curve.

implementation schedulingMike noted the challenge the mill faced with this

project. “Our major challenge was just being able

to schedule it so we could do it with no loss of

production. USNR worked with us very well so we

The value of backside scanning

was recently proven out in a

comparison at this hardwood mill.

“It’s definitely a cost effective

enough difference to make it

worth pursuing.”

Mike Frantz, Allegheny Wood Products

SEEING BOTH SIDES

aLLEGEHEnY WOOd prOductS putS duaL ScanninG carriaGE OptiMiZatiOn tO tHE tESt, and prOvES itS WOrtH

Millwide INSIDER | ISSUE 5 - 2011 4

could do all the installations over the weekends

and get everything done. It was critical for us that

we didn’t incur any downtime.” Installation was

completed over three weekends in April and May of

this year.

Jeff Storey, USNR project manager, handled the

many varied details of the project from the supplier

end and liaised between the two teams – customer

and vendor. He commented, “Mill management was

very specific about scheduling, and knowing their

milestones made it very easy to set the schedules

with the various resources from USNR to meet the

mill’s requirements.”

proving the value of backside scanningAt the same time that it was implementing the

new carriage optimization systems, the mill

took advantage of the chance to set up the two

carriages with differing approaches for the scanning

component. One line was fitted with both front and

backside LASAR scanners while the second line

received only a front side scan unit. This allowed the

mill to perform a detailed analysis and comparison

between the two configurations to determine the true

value of dual scanning systems.

Jeff Storey weighed in on the increased value with

backside scanning. “The backside scanner allows

for a better full breakdown solution by knowing what

the contour of the log is on its backside. The fit for

products becomes much more accurate with that first

opening cut. Without it the system has to use knee

locations to extrapolate the backside shape of the

log, which is never as accurate.”

Mike Frantz explained the mill’s process for the

comparison. “For our mill study we used 200 logs. We

split them up between the two lines so we would have

the same number of logs in each. There were a variety

of sizes and grades and amounts of defects, but we

made sure both batches were equal. We wanted to

determine how both lines would handle the upper and

lower grades. We ran all those logs through and we

were able to get a very good comparison between the

two lines. We discovered a very significant difference

in favor of both front and backside scanning.”

With such positive results AWP is considering

adding backside scanning to the other carriage

optimization system, though no firm decision has

been made. When asked his level of satisfaction with

the LASAR/MillExpert combination Mike said, “Overall

I am very satisfied. We did see an increase in our

yield per log. And we did see an increase with front

and backside scanning versus front side scanning

only. It’s definitely a cost effective enough difference

to make it worth pursuing.”

application matched solutionIn certain circumstances the mill required a face

order change from the full breakdown solution, and

MillExpert is designed to provide this capability.

Jeff Storey explains how this process works. After

the first face is sawn, the typical solution would call

for the sawyer to proceed to the opposing face (180

degree turn) to finish the log. With the Kingwood

mill’s application processing certain log types and

shapes, it is advantageous to be able to first turn the

log 90 degrees and saw a few cuts before continuing

on to finish the solution on the opposing face. When

making this first turn, the system provides the sawyer

with a minimum opening face (MOF) scan so any

number of cuts can be made at his discretion. This

allows him to resize the center cant of the log for

more efficient processing at downstream machine

centers. With the solution being maintained or

rescanned on the final face, the sawyer can continue

A face order change feature, built into the MillExpert system, allows the sawyer to turn the log 90

degrees. The system provides a minimum opening face scan and the sawyer can make any number of

cuts at his discretion. This allows him to use the original cant solution, or resize the center cant for more

efficient processing downstream.

“For our mill study we used 200 logs.

We ran all those logs through and we

were able to get a very good comparison

between the two lines. We discovered a

very significant difference in favor of both

front and backside scanning.”

Yield per log has improved since AWP upgraded its two carriage systems

with MillExpert optimization and LASAR scanning.


to use the optimization rather than causing an “out

of sequence” situation where he would be required

to finish the log with manual decision making as

opposed to an optimized solution.

Jeff also explained that customization was done

to the control consoles and hardware to reduce the

time required to switch over to the new system, thus

ensuring the mill’s timeline for implementation.

Mike Frantz commented, “The system is only ever

as good as the people operating it, but MillExpert

makes it very easy. It is very user friendly for people

to work with.” This level of satisfaction with the

MillExpert platform was the overriding motivation

for the upgrade to the mill’s trimmer optimization

system. Mike explained, “The primary reason was we

wanted to have a standard platform throughout the

mill.” The existing USNR V6 scanning system on the

trimmer was retained, while the TimberGrafx platform

was replaced with MillExpert.

Giving credit Mike was very complimentary of the support received

from John Seifert, USNR account manager who

Mike described as “fabulous to work with”, and Jeff

Storey, USNR project manager who also handled the

training. AWP sent six of its personnel to USNR’s

Eugene, Oregon facility for in-depth training on the

MillExpert carriage optimization system. Mike said,

“The training went extremely well. Some of us were

already familiar with the MillExpert platform.” And

he highly recommends anyone who is upgrading

their system to consider travelling to one of USNR’s

sites for training because it allows uninterrupted

focus while learning. Though not required for

training, Mike made sure that AWP personnel who

took part in the training were supplied laptops

loaded with the MillExpert software so they could run

simulations offline. This is only one demonstration

of AWP’s commitment to achieve the utmost from its

investment in new technology.

In addition to Mike Frantz, AWP personnel

who were involved with this project included Tom

Plaugher, VP of operations; Mark Wilson, plant

manager; Stan Ziemba, Shift 1 mill supervisor;

Jason Clay, IT specialist; and Donald Sypolt,

trimmer operator.

Smart growthAWP is an independent, family owned business with

seven of its eight holdings located in West Virginia,

and the eighth in Pennsylvania. Its forward thinking

attitude brought this company a long way in its 40

years from a single hardwood mill to what it is today.

The company is operated by John Crites Sr., John

Crites Jr. and Pat Crites, who continue to invest

heavily into their company. As a result it has grown

tremendously to include three green sawmills, three

sawmills with dry kilns on site, and two dry kiln

concentration yards.

Proof positive of AWP’s philosophy to maintain

its competitive edge through technological

opportunities is the prominence it has given to its

IT arm. Mike Frantz leads a team of IT specialists

who travel between the eight AWP sites. The team

maintains the computerized systems, and together

with the site managers they look for prospective

efficiency improvements for each stage in the

process. It’s a recipe that has helped the company

weather the storm, remaining competitive at a time

when others in the hardwood realm have faltered.

Mike has been working with the company since 1997

and he comments, “ I would definitely say AWP is

very progressive, and management has come to trust

in the analysis we (the IT group) provide.”

He also reflected, “The climate for the hardwood

industry is very difficult right now. AWP has

continued to be successful because of its persistent

efforts to increase efficiency. Some quite large

companies in this sector have gone out of business

because they didn’t invest in their infrastructure.

Efficiency is king and they could not keep up.”

With its passion for progress, AWP continues with a

positive outlook to invest in its success.

AWP’s Mike Frantz is a strong proponent of the

MillExpert platform. “The system is only ever as

good as the people operating it, but MillExpert

makes it very easy. It is very user friendly for

people to work with.”

“Overall I am very satisfied. We did see an

increase in our yield per log. And we did

see an increase with front and backside

scanning versus front side scanning only.”


Doug Strasky leads the primary breakdown

optimization team for USNR. USNR’s team of talented

and dedicated engineers, project managers and

technical service personnel are based at facilities

at Parksville and Salmon Arm, BC, Eugene, OR and

Woodland, WA. Doug explains the approach USNR

has developed for carriage optimization in softwood

and hardwood processing applications.

Q. How does carriage optimization differ when processing softwoods or hardwoods, and what is the MillExpert approach?

a. Softwood breakdown solutions are generally

based on specific board target sizes and value

recovery using wane rules and values for different

grades to drive the optimization. The carriage

operator in a softwood mill is typically focused on

processing the solution from the optimizer as quickly

as possible. These operators rely heavily on the

scanning and optimization systems to achieve the

best solution and provide accurate carriage sets to

achieve that solution every time. They don’t want to

waste time over-riding the optimizer.

The MillExpert optimizer also uses sophisticated

modeling of the production costs at the carriage

as well as at the downstream machine centers in

the mill, so that its solutions provide the highest

production value.

Hardwood breakdown generally relies on

extracting the appropriate products from the

different concentric grade zones in the log. There

are usually more grades of products

than for softwood, and timbers are more

common. The MillExpert allows defining

the concentric grade zones in the log

and associating specific products with

these grade zones, so optimization for

hardwood is typically driven by these

grade zones. This can mean more

stages to breaking down each log as the

biggest, high grade products are taken

from each surface of the log before

moving on to the next grade zone.

MillExpert models these stages in the

breakdown so that the solution is based

on the cuts that will actually be made

to the piece. Some other systems on the

market base their solutions on a generic

block that represents only a portion of the

log’s model.

Q. is there anything else that differentiates MillExpert for hardwood carriage optimization?

a. MillExpert offers autograding as an option. This

feature allows the optimizer to consider the diameter,

sweep, taper, nodal swell and presence of flare to

automatically determine a grade for each log. The

grade rules can set the relative sizes of the concentric

grade zones as well as the breakdown rules and

products used. This feature can help all carriage

operators achieve consistently high grading accuracy.

(See page 8 for more information on this feature.)

Q. How does the addition of backside scanning assist in optimizing a solution for carriage systems?

a. A system with both front and backside scanning

ensures an optimized solution using complete, whole

log scan data. The log’s first cut on a carriage

becomes the reference for the rest of its breakdown.

In a sense it locks in the rest of the solution, so all

of the important decisions have to be made before

the first cut. This includes the size and offset of the

center cant and the cuts that will be made on the

back of the log. Using backside scanning is the only

way to ensure the optimizer has complete, accurate

data on which to base the solution. The result will

be higher value recovery from the log. Backside

scanning eliminates the need to re-scan when the

log is turned, thus increasing throughput.

If you have a question about your carriage

optimization process, call us at 800.BUY.USNR and ask

one of our many experts.

The image shows a log scanned with both front (red data

points) and backside (blue data points) LASAR sensors,

illustrating the amount of data that is captured from each of

the sensors. It is clear that backside scanning provides much

more complete information about the true shape of the log.

For more than a decade USNR has been in the

business of designing carriage optimization systems

based on the MillExpert platform, with nearly 100

such systems ‘under our belt’ in both softwood and

hardwood applications. We explore some of the key

attributes of the system that differentiate it from

others on the market.

“Mill”Experts inCarriage Optimization


Highest yields. Maximum profits.Grade sawing solutionsUSNR’s Carriage Optimizer system is completely configurable combining the industry’s highest density scanning with extremely versatile optimization software.

Fast and accurate scanning LASAR is the rugged and reliable sensor able to scan both sides of a log with unparalleled resolution. The results are incredibly accurate opening faces with only one scan and one set!

Advanced cutting modesUSNR’s advanced system enables you to implement even the most complex solutions including MOF+, Whole Log BOF, and Optimized Grade Sawing. Now you have control of your product mix.

LASAR CARRIAGE

Millwide. Worldwide.

www.usnr.com800.buy.usnr [email protected]


One valuable option available with the MillExpert

platform for carriage optimization is the capability for

autograding. MillExpert carriage optimizers may use

autograding rules and a grader object in the MAL to

automatically assign scanned logs to a fiber grade.

(Note: The operator’s console must have an autograde

button installed and connected to the PLC.)

autograding rules for fiber gradesMillExpert’s autograding assigns logs to fiber grades

depending on whether the logs have (or don’t have)

these six characteristics:

► flare

► kink

► nodal swelling

► knots

► sweep

► fluting

Each of these characteristics can be classed as:

► required ► not allowed ► scored

The log is analyzed to see which of the required or

not allowed characteristics are present, at least to

the degree specified in the threshold settings.

Step by step: How autograding worksFor each scanned log, these steps are carried out for

each grade.

1. The log is checked to see whether it fits within the

small and large end diameter restrictions defined for

the grade. If it does not, then the log cannot belong

to this grade, and the next grade is checked.

2. Each log starts out with a default score that can

be used to control the grade when no characteristics

are present.

► For each required grade characteristic that is present

in the log beyond the predetermined threshold

setting, the score is increased by the weighting

► For each not allowed grade characteristic that is

present in the log beyond the predetermined threshold

setting, the score is decreased by the weighting

► Scored characteristics mean they change the score

when they are present but have no affect if they are

not present.

3. For each grade, the scores for all characteristics

are added together. The log will be assigned to the

fiber grade that yields the highest score. If two or more

grades share the highest score, then the log will be

assigned to the grade with the highest grade priority.

calibrationCalibrating the autograding feature will finetune how

MillExpert assigns logs to fiber grades. It should be

done at system startup, when a new fiber class or

grade is created, or if major changes are made to the

mill’s log diet. MillExpert provides a user interface

that shows how each feature is scored on each log,

the total points, and the final grade chosen by the

auto grading feature.

autograding in practiceAutograding is a very powerful tool that can

assist producers to achieve the highest return

on log resources paired with MillExpert carriage

optimization. For example, a log with significant

sweep is less likely to have high grade wood, so a

mill can choose to cut a pattern with a larger cant

and fewer sawlines at the carriage. Similarly, nodal

swelling indicates branches that have been removed

from the log. This log will yield lower grade lumber

because there won’t be any clear jacket boards.

For help setting up autograding on your MillExpert

carriage optimization system, contact USNR service

at 800.BUY.USNR.

For more information on the MillExpert

optimization platform for any machine center, contact

your local USNR representative, or 800.BUY.USNR, or

e-mail us at [email protected].

characteristic threshold measurement

Flare Inches of flare/inch of log length

Kink Degrees of kink

Nodal swelling Percent of nodal swelling

Knots Maximum knot height

Sweep Sweep expressed as a %

Fluting Maximum flute height

autOGradinG FOr MiLLExpErt carriaGE OptiMiZatiOn

Ask a Technician


For Louisiana Hardwood Products (LHP) at LeMoyen,

Louisiana, an abundance of short length material

was creating bottlenecks and jam ups at the edger

infeed. At the same time two operators were required

to run the edger system; one operator monitored and

facilitated the flow at the top of the unscrambler, while

another manned the operator’s cab and could override

the optimizer’s decisions based on the grade of each

piece. The mill set out to improve the throughput and

streamline the process. The chosen solution combined

machinery, process controls and optimization in an

integrated blend designed by USNR.

The LeMoyen mill processes a wide variety

of hardwoods including red and white oak, ash,

cypress, elm, pecan, sycamore, and more. Most

of the supply is harvested from company-owned

land within 100 miles of the plant. Its products are

marketed both domestically and overseas through

Anderson-Tully Worldwide, to serve the flooring and

furniture markets.

The LHP team, headed by Operations Director

Butch Morgan, knew they could vastly improve the

performance of the edger system. Butch commented,

“We realized that we had a bottleneck at our edger.

We weren’t getting the throughput we needed to,

and our scanner was not being allowed to do what

we needed it to do. The operator was positioned

such that he could override the scanner and that was

slowing the process down. The system wasn’t able to

make the decisions it needed to make.”

The first challenge the mill faced was simply

deciding what would best fit the requirements from

what was available in the marketplace. Butch said,

“We did our due diligence and shopped around, and

we always came back to USNR simply because of the

experience we’ve had.” The mill already had USNR’s

MillExpert optimization on its edger, trimmer and

headrigs, and the team was comfortable with it and

with USNR from a service standpoint.

Engineering the transformationThe next challenge was to engineer the changes that

would build in the correct balance for improving

the flow while keeping the design as simple and

efficient as possible. Mechanically, the existing ‘S’

shaped unscrambler was changed out for a new,

radius back design to improve feeding consistency,

and a new tipple gate was installed to drop out scrap

Sometimes improving throughput

and efficiency requires a more

complex fix than changing out

a machine center, upgrading

the process controls or the

optimization package. Sometimes

it requires an approach that

transforms the entire process.

Engineering a process evolutionLOuiSiana HardWOOd rEdESiGnS itS EdGEr LinE

ADD CHAIN LINES NEW TIPPLES

NEW TIPPLE SHAFT NEW HEAD SHAFT

NEW IDLER ASSY

NEW CHAINRACEAND LUG CHAIN NEW SPOTTING CHAIN RACE,

CHAIN AND JUMP PLUMBING

NEW UNSCRAMBLER6’ RADIUS BACK

NEW HEAD SHAFT

NEW AIR TAKE UP


from entering the edger infeed area. Chainways were

added at some of the wider chain spacings to capture

the shorter lumber, while processing changes were

made upstream in an effort to remove scrap pieces

from the flow. This solved one of the major problems

that was impeding the flow of material to the edger.

The edger itself is a Schurman design circa 1989.

It was deemed to be adequate for the job with four

shifting saws, but one of the outside saws was not

on a positioning cylinder and so provided limited

movement. This impacted the mill’s ability to

recover value. A positioning cylinder was installed

to facilitate shifting the outermost saw to alleviate

this issue. New variable frequency drives replaced

the old hydraulic drives which also improved

processing efficiency.

The existing Modicon controls package was

replaced with ControlLogix, and two MillTrak

systems were installed to monitor the flow.

(See page 11 for information about the

MillTrak lumber flow management system.)

One MillTrak monitors the top of the

unscrambler leading onto the positioning

pins and tipple gate through to the scanner; the

second one monitors the lumber after the scanner to

the outside pressrolls and positioning pins feeding

the edger.

the MillExpert solutionThe MillExpert optimization package was upgraded

to the latest version with new computer hardware,

while the existing Geo2 scanning system was left

in place. The MillExpert edger optimizer analyzes

scanned lumber images in 3-D, accepting data

from the existing scanners. The optimizer evaluates

all allowable products and combinations of those

products that can be made from each flitch.

MillExpert edger optimization software allows

for board products to be fit into the flitch in real

time, and is proven on virtually every type of

edger machine configuration including: multi-saw

edgers with combinations of fixed and shifting

saws, chipping edgers, and various reman head

configurations. MillExpert is easily adapted to model

the traditional transverse edger as well as single or

multi-zone lineal edgers with ‘smart pickers’. This

system utilizes exhaustive-fit optimization, with no

lookup tables, patterns, profiles or matrixes used

in this technique. This assures the absolute highest

value solutions possible.

Ben Whitaker was USNR’s project manager for

this project, and Gilbert Aponte, a USNR technical

expert in optimization and controls, oversaw those

aspects as well as installation and training. Gilbert

explained that after the original MillExpert system

was installed, USNR added the NHLA rules to the

edger software. So with the installation of faster

computer hardware and updated software, the project

allowed the mill to take advantage of some of the

new capabilities already built into MillExpert for

hardwood processing.

MillExpert is designed to be a chameleon; it has

the ability to handle a wide variety of processes by

Mechanically, the existing ‘S’ shaped unscrambler was changed out for a new, radius back design to improve feeding consistency, and a new tipple gate was installed

to drop out scrap from entering the edger infeed area. Chainways were added at some of the wider chain spacings to capture the shorter lumber, while processing

changes were made upstream to remove scrap pieces from the flow.

After the original MillExpert system was

installed, USNR added the NHLA rules to

the edger software. So with the installation

of faster computer hardware and updated

software, the project allowed the mill

to take advantage of some of the new

capabilities already built into MillExpert for

hardwood processing.

MOdiFiEd EdGEr inFEEd LaYOut

The screen at right shows a board solution from the

LHP edger system highlighting some of the unique

features built into the the MillExpert to accommodate

hardwood applications. In this example, MillExpert

allows the edger system to recover both a 5.9” wide

full length board and a 3.6” wide 4’ recovery piece

with the targeted parameter sets available.

(See also Page 13.)


changing the system’s parameters to fit the exact

application. USNR’s engineering team develops

the parameters based on what the customer wants

it to do, and the system’s abilities based on those

parameters can be turned on at the outset, or later

depending on the customer’s process. Gilbert

explained, “LHP’s original parameter sets were

brought into the upgraded software, and that is

what they started out with. Then, during the training

we showed them how to expand the system’s

capabilities by simply making adjustments to the

parameters.” (Screen examples for parameter sets

are shown on page 13.)

achieving process evolutionButch explained the new process after all the changes

were made. “We actually don’t have an operator

at the cab any longer, we have him down at our

unscrambler. His main duty now is to control what

comes across the unscrambler and tipple out any

unwanted pieces we don’t want to get into the edger

infeed. The optimizer now makes all the decisions for

edging the piece, and it’s doing an excellent job.”

The operator is also able to input grade or product

information as each board is presented. The optimizer

takes that information into account when it makes its

solution for processing the piece. For example, if the

operator sees that the board presented is pallet stock,

he can input that information so the optimizer takes

it into account for the edge solution. The MillTrak

systems also facilitate this redesigned process.

Of note, Gilbert Aponte worked at this mill in the

1980’s when it was owned by Roy O Martin Lumber

Company. He was the plant technician at the time,

and had his hand in almost all of the processes at

the site. When the original scanning system was

installed by USNR in the early 1990’s, Gilbert was

working for USNR and handled the installation.

Gilbert was able to shed much light on the process,

both before and after this current evolution.

Of the original process, Gilbert says, “It was

designed with a specific focus in mind and it

served that purpose. Now we needed to take a new

approach, remove some of the steps that were built

in to the original process and try to simplify it. That

took mill personnel and USNR engineering staff to

come up with the most cost effective way to make

the transformation occur.” He explained that, in

doing so many components were reused and recycled

back into the new design. One of the challenges

for the team was to be very careful not to remove

something that could be reused in the design, and it

required everyone involved to work together to create

a process that is effective in today’s market.

improving piece countThe overriding goal the mill had set for the project

“LHP’s original parameter sets were

brought into the upgraded software, and

that is what they started out with. Then,

during the training we showed them how to

expand the system’s capabilities by simply

making adjustments to the parameters.”

MillTrak is a vision-based lumber flow management

system. It maximizes throughput efficiency utilizing

a camera that is mounted above the lumber transfer

to provide a clear view of the flow. It can detect the

presence and position of lumber as it passes through

the camera’s field of view; accuracy is dependent

on the camera’s position and distance from the

lumber deck being monitored. Its location above the

lumber flow reduces its susceptibility to the dust and

moisture that often hinder photo-eye and proximity

detection systems.

MillTrak creates a virtual array of presence

detection points along the lumber conveyance. As

lumber pieces travel through the detection area, the

system is able to recognize the presence or absence

of lumber as well as its width, length and skew.

Through adaptive hook sequencing, the hook

timing can be adjusted based on the lumber’s

width. If a skewed piece is detected, extra space

can be created by having the hooks remain up until

the piece has straightened, reducing the need for

operator intervention. The virtual array can be easily

modified through software and does not require

the physical relocation of numerous photo-eyes

and proximity sensors. Much of the conventional

PLC logic can be simplified to use less timer logic

replaced by more accurate proof of detection logic,

allowing for better optimization of timing for lug

chain loading and smoothing the flow. Optimizing

lumber flow maximizes the efficiency of the process

and reduces the overall cost of ownership.

Damon Clinch is one of USNR’s process control

experts who has an intimate knowledge about the

MillTrak system, having installed many of the units

in mills around the globe. “There is basically one

critical component and that’s lighting/contrast.

When lighting is even and consistent, and where

there is adequate contrast to easily differentiate the

wood from the background, then MillTrak makes the

job easy.”

The MillTrak system was launched in late 2009

and today 35 systems have been sold with numbers

increasing substantially over the past year. Also

available is the MillTrak 3D system for optimizing

log flow at the primary end.

Following are some of the applications MillTrak is

designed to benefit.

► Planer infeed backlog

► Edger unscrambler feeding a lug chain

► Trimmer lug loader backlog

► Cant hook deck sequencing

► Adaptive hook timing based on product width

and skew

► Stacker layer sequencing

MiLLtraK MOnitOrS tHE FLOW


was to improve throughput and efficiency. Butch

related that previous piece counts were in the range

of 10 pieces/min. or below, and even that wasn’t a

consistent number. “We set out to consistently get

4 pieces/min. increase in the flow. If we can get

lumber to the system we can consistently do 13

pieces/min. We’re also contemplating more projects

in front of the edger to try to get a few more pieces

to the edger. I think the system will do exactly

what we want it to do.” He went on to comment

on the improvement in recovery. “Removing the

opportunity for the operator to override the scanner

and letting the scanner do what we put it in to do,

we’ve realized recovery to the tune of about 2%. It’s

hard to quantify that as we’re still evaluating.”

Butch says that he is extremely satisfied. “We’re

still training folks and we learn something new every

day. It’s been a learning curve for us.” Training was

handled on site by the USNR start-up team. Butch

also related that training was extended upstream from

the edger all the way back to the headrigs. “One of the

biggest challenges for us is trying to keep unwanted

pieces and junk away from our edger system. That’s

been a training process for everybody.”

all systems ‘Go’Throughout the project’s duration Butch was pleased

with the support from USNR, and even more so of

the start-up crew. “USNR had an excellent start-up

team here for us from controls to mechanical, and

optimization. We started this thing up in a short

amount of time.”

LHP personnel involved in the project were as

follows. James Stroud, electrical superintendent,

was involved with the electrical layout, system

start-up, and working with USNR system

programmers. Rob Blankenship, production

manager, was involved with production flow,

training, and working with USNR controls

technicians to understand the new system. Wayne

Fontenot as production superintendent, worked

with the start-up team during the changeover. He

was heavily involved with training at the edger, and

also training the operators upstream on the quality

of pieces that had to get through to the edger to

ensure the transformation of the process was a

success. Greg Thibodeaux, mechanical supervisor,

worked with USNR service technicians and Pierce

Construction, a local contractor, on installation of

the new mechanical equipment. Wayne Fontenot,

James Stroud, and Heath Broussard, supervisor

responsible for quality control, all worked closely

with the USNR team setting the new software

parameters for the system. And Butch Morgan was

involved with the project from beginning to end.

Butch’s next focus for the site will be finding

ways to increase the sawing speed, with attention to

upstream processes. He says the hardwood market

is primarily species driven. “While the red oak

market has softened somewhat, we’re managing

to keep our head above water.” The evolution this

project has made to the mill’s process in terms of

efficiency, throughput and value recovery further

support that cause.

With the new process a single operator runs the entire line.

“Removing the opportunity for the

operator to override the scanner and

letting the scanner do what we put it in

to do, we’ve realized recovery to the tune

of about 2%. It’s hard to quantify that as

we’re still evaluating.”

“We actually don’t have an operator at

the cab any longer, we have him down

at our unscrambler. His main duty now

is to control what comes across the

unscrambler and tipple out any unwanted

pieces we don’t want to get into the edger

infeed. The optimizer now makes all the

decisions for edging the piece, and it’s

doing an excellent job.”


The world of hardwood processing is different from

that of softwood dimension mills. Many optimization

platforms on the market are simply not designed for

the intricacies that the hardwood industry demands.

And that is why MillExpert has gained a very strong

approval rating among mills in this sector.

USNR’s team of optimization specialists includes

several who are well versed in the hardwood

processing realm. Their expertise dates back to

NHLA and hardwood algorithms based on the

INOVEC WaneMaster.

Product configuration in the MillExpert edger

optimizer is familiar and intuitive. The configuration

of cuttings is set up to mirror the NHLA grading

rules. The tally rule allows control over the

value used by the optimization. Commonly-seen

variants of NHLA tally are offered in addition to

the standard rule, as well as the options of end

tally and block tally. Along with powerful control

over wane allowances, the user is able to take

full advantage of MillExpert’s built in product-

by-product configuration. Wane free clear cutting

evaluations can be set up to work in conjunction

with the optional BioVision feature, providing grade

recognition capability. These features combine

to provide maximum control over the system for

producing higher quality products.

Contact us for more information about our line

of products designed specifically to meet the

requirements of the hardwood processing sector.

The screen above demonstrates an FAS cuttings solution evaluation with BioVision. Using the wane

parameters, knot allowances and required yield, the board will be cut to 10.7” wide with three clear cuttings

totalling 124 clear cutting units. If the board were wider or longer its surface measure would round to 13

and the cuttings would no longer meet grade requirements due to knot and wane constrictions.

The Scale Table below demonstrates how the value of a board can be configured by both length and

width. Scale tables are set by length and width. Other hardwood-related parameters are shrinkage for

surface measure determination, push/pull logic and tally rule type.

The cutting rules configuration dialog (left) mimics the

Hardwood Lumber Grades Standard Inspection method.

MillExpErt: hardwood procEss ExpErt




USNR’s new BioLuma 2900 sensor delivers color images and color solution plots for each board scanned.

More hardwood edger optimizers than all others... combined!

HARDWOOD EDGER OPTIMIZER

The clear leader in optimized hardwood applications, our MillExpert Hardwood Edger Optimizer is designed with your products in mind

► Wane-free clear cutting evaluations; works with optional BioVision for visual grade recognition capability

► Considers true random or fixed widths, or a combination► Independent wane controls for each edge► Largest, most experienced support staff in the industry

MillExpert Hardwood Edger Optimizers can be applied as

► new systems► upgrades to Inovec, Newnes, or USNR optimizers► retrofits to existing systems with alternate scanners

Combining dense 3D scan data with the power of today’s high speed computers, MillExpert Hardwood Edger Optimization lets you get the most value from every board you edge. For an evaluation of your system, call us today!


USNR’s insulated floor is designed to retrofit existing

dryers of all configurations. New floor panels

fabricated from mild or stainless steel are installed

over the existing concrete floor that is typically

found in most older dryers. Complete seal weld

installation literally eliminates dryer leakage around

the foundation, and keeps thermal energy inside the

dryer to improve dryer productivity.

The insulated floor upgrade significantly

enhances dryer performance and gives new life

to your existing dryer, all with a minimal capital

investment. Improved dryer alignment and

expansion reduces plug ups and lost operating time.

Foundation sealing that is normally required around

door frames is eliminated.

Benefits include the following.

► Reduces energy consumption

► Improves dryer productivity

► Prevents further foundation deterioration

► Eliminates leakage

► Easier cleanout

With decades of success in veneer drying, we know

that uninterrupted performance and high quality

veneer production is critical in today’s challenging

operating environment. Get the most out of your

system with unique and reliable upgrades from USNR

that are designed by the people who understand

veneer processing machinery better than anyone in

the business.

Contact us today at [email protected], or toll-free

800-BUY-USNR.

Insulated dryer floor panels are

easy to install over the existing

floor, and provide significant

efficiency gains.

New insulated dryer floor panels



USNR’s new BioLuma 2900 sensor delivers color images and color solution plots for each board scanned.

More hardwood edger optimizers than all others... combined!

HARDWOOD EDGER OPTIMIZER

The clear leader in optimized hardwood applications, our MillExpert Hardwood Edger Optimizer is designed with your products in mind

► Wane-free clear cutting evaluations; works with optional BioVision for visual grade recognition capability

► Considers true random or fixed widths, or a combination► Independent wane controls for each edge► Largest, most experienced support staff in the industry

MillExpert Hardwood Edger Optimizers can be applied as

► new systems► upgrades to Inovec, Newnes, or USNR optimizers► retrofits to existing systems with alternate scanners

Combining dense 3D scan data with the power of today’s high speed computers, MillExpert Hardwood Edger Optimization lets you get the most value from every board you edge. For an evaluation of your system, call us today!

New floors for your old veneer dryer


Sorting lumber can seem daunting when faced with

the vast number of variables at play in most modern

mills. How many sorts do we require? How do we

accommodate more grades within our existing

sorting system? How do we increase our operational

throughput and still sort effectively? How do we deal

with wet boards or MSR? What do we do with the

partially filled bins at the end of the shift? How can

we do more with a finite number of resources? How

do we give our customers more of what they want,

and less of what they don’t want within acceptable

grade rules? Fortunately USNR has the expertise to

sort out these issues – pardon the pun.

With thousands of sorter installations worldwide,

USNR’s lineage boasts brands such as Newnes,

Hemco, CSMI, LSI, Coe, Irvington Moore and others.

USNR has many decades of experience solving

a multitude of lumber sorting problems. USNR’s

Newnes brand offered the first vertical bin sorter to

lumber producers decades ago, and today features

the widest array of advanced technology solutions.

USNR’s sorter tops include J-bar, pusher lug and

drag chain; sorter bottoms include vertical bin, slant

bin, slant tray, horizontal tray and sling. We design

for speeds up to 240 lugs per minute. High speed

bin sorter options comprise the following.

► bin chokes

► bin baffles/dividers

► bin kickers (new)

► stub bin walls

► fully sheeted bins

► live bin walls

► bin safety lock cables (LNS)

► sweeper chains below sorter

► wireless bin attendant

► auto bin dumping and auto package tracking

WinTallyUSNR’s WinTally® is the leading contender in sorter

management systems. WinTally V7 operates on

the Windows 7 platform, with SQL Server 2008 R2

Express database, Crystal 10 reporting and Ethernet

IP. Standardized code offers excellent support and

upgradeability. WinTally is capable of a multitude of

complex sorting configurations. Following are a few

of its key features that set it apart from other tally

systems available today.

► Bin dispersion: allows the tally to disperse

products throughout a bin. E.g. the system can

create packages with an even dispersion of low

grade #2 boards within a package of higher

grade #2.

► Product mixing: allows a mix of products within

a bin. E.g. a customer may want to offer a deal

to end users where they can purchase packs

containing a certain percentage of ‘wet’ boards in

a #1 pack, or to mix packs by species.

USNR’s capable lumber handling

team takes the mystery out of

lumber sorting, with a wide variety

of solutions that are time tested

on a global scale. Whatever your

challenges, we can help you make

the right choice.

WinTally’s user interface offers control of a host of sorting configurations.

USNR sorts it out for you


► bin throttle: limits the number of boards that

can be directed to a single bin or area so as not

to overwhelm the bin or pull chain area while

allowing mill personnel the ability to maintain

control of the process.

► Jag pack management: A jag is a bin that is

not completely filled, and typically occurs at the

end of a shift. If a different product will be run in

the next shift, the bins must be cleared out first,

causing production loss on re-entry when that run

is used again. This feature minimizes the number

of jags remaining at the end of a shift by shutting

off products at the optimizer once those bins are

filled. The optimizer must then re-optimize these

products into a different grade, minimizing jags

while maintaining the highest value combinations.

Optimizer integration ► Reduced product setup; enter products ONLY at

the LHG or THG

► Offers increased product control to enhance

product mixing

► Built in board logging from the LHG or THG;

WinTally automatically saves selected board

images for diagnostics

Integration with USNR’s Lineal High Grader (LHG)

or Transverse High Grader (THG) in the planer mill,

and trimmer optimizer in the sawmill ups the ante

for the WinTally, however it is not essential.

When WinTally is integrated with the LHG or THG

the products are entered only once in the system,

at the optimizer. The optimizer’s board solution

is relayed to the WinTally system for sorting.

Further, if a mill is cutting to order, once the

order is filled the optimizer no longer makes that

product. Instead it will select the next most valuable

solution. This could be a cut-n-two or single board

solution depending on the value of currently active

products (based on mill inputs) and the physical

characteristics of the piece.

When WinTally is not integrated with LHG or THG,

the products must be entered at both the optimizer

and at the WinTally. As an example, product mixing

can work in a stand-alone WinTally system used with

another vendor’s optimizer. In that case the product

is not “turned off” at the optimizer but can still be

mixed throughout specified bins.

Features, features, featuresThere are many other standard features offered with

WinTally besides those described previously.

► Sort-to-order capabilities. Any number of

products can be sorted for specified packages.

The sort definitions will self-disable when the

order entry count has completed.

► Flexible sort setups for each product run. New

products can be added at any time.

► product sorting by priority allows specific

packages to be produced in a sequence regardless

of their location in the sorter.

► trim-by-product capability allows a product

arriving at the trimmer that does not appear in

the active product list to be trimmed back to an

allowable product.

► virtual bin: direct multiple sorts to any location.

Typically used where a dropout sends a number

of products to a pull chain for hand sorting. Each

of these products can be defined, tallied and

reported the same as products sorted to bins.

► Multiple MSr board tests can be run

simultaneously. This allows much enhanced

testing functionality.

► End spray and grade stamp boards by product

and/or grade.

► Multiple views of bin data are available, and the

bin overview screen shows the product-by-product

count per bin.

► Dual bin search zones, configurable per sort.

► A real-time board display maximizes feedback and troubleshooting, configurable by the user.

► Database can be backed up and restored through

the user interface, with no loss of board counts in

the bins.

Machine configuration ► vFd speed control setup from WinTally is

configurable per product run.

► adjust pLc timing points (user customizable).

► Chain stoppages can be forced, based on the

occurrence of specified alarms. The alarms can

be allowed to occur to a predetermined limit

(customizable by site).

► Any alarm can be configured to accumulate

downtime for reporting purposes.

► interfaces with uSnr Grade Mark reader to

configure grade mark setup, per run.

► interfaces with uSnr’s LHG or tHG for grade

tests and for single point product setup.

Shift configuration and data reporting ► create complex swing shifts and report printing

instructions, then track production to a crew even

when complex shifts exist.

► Reports are designed in Crystal Reports, and offer

up to 1000 shifts of historical data.

USNR’s sorting expertise offers many more options

and features. Please contact us at 1.800.BUY.USNR,

+360.225.8267, or [email protected].

WinTally interfaces with USNR’s grade mark reader.


NEW

PR

OJE

CTS

aKd Softwoods - Edger infeed improvementsThe Associated Kiln Driers site at Colac, New

Zealand is updating the infeed at its transverse

edger system with new unscrambler, transfers and

positioning table. USNR will work with Skookum

Technology to implement the improvements.

allegheny - Edger upgradesAllegheny Wood Products at Kingwood and

Norton, West Virginia are upgrading their existing

V6 Edger systems with MillExpert optimization.

ames true temper - Kiln boss upgradeThe plant at Wallingford, Vermont is upgrading

its Kiln Boss controls system to allow for current

and future functionality enhancements.

building products of canada - coe dryer dry End Seal systemThe company’s Coe Fibreboard Dryer, located at

LaSalle, Quebec will receive a retrofit with a new

dry end seal system including powered exhaust

fan. The purpose of the upgrade will allow two of

the end zones to operate under slight negative

pressure, reducing the fume leakage into the

plant and preventing ambient air from entering

the dryer through the cooling sections.

california redwood -trim Line modificationsThe Korbel, California site has ordered

modifications to its planer mill trim line along

with a new slant hopper stick/lath placer.

parton Lumber - MillExpert/LaSar log optimizationParton Lumber at Rutherfordton, North Carolina,

has ordered a MillExpert log optimizer with

two LASAR scan heads for its carriage system.

The MillExpert software will feature rotation

optimization, using actual whole-log solutions

to evaluate the best log orientation, not just

simple sweep.

Warm Springs Forest products - Edger top reman chip head moduleThe mill located at Warm Springs, Oregon is

adding a top reman module behind its existing

Schurman board edger.

West Fraser - planer mill modernizationsWest Fraser is modernizing its planer mills

at Hinton and Whitecourt, Alberta. At Hinton,

significant modernization will be done including

a quick change head conversion to its Coastal

planer. The Whitecourt site will also receive

major modernization to its planer mill.

Western Forest products - trimmer optimizer upgradeWestern’s Nanaimo Sawmill Division is

upgrading its trimmer optimization from the

QNX platform to the latest USNR Sawmill Suite

release, V7.1.

arkansas plywood producer - 3 main cylinder replacementsA major plywood producer in Arkansas is

replacing three main cylinders on its Coe

plywood press. The heavy duty design of the new

cylinders will fit into the same envelopes as the

old. The new cylinders will also provide longer

life with excellent tolerance for high stress and

pressure spikes.

USNR was pleased to sponsor free tickets to a

NASCAR race for four lucky folks who visited

our booth at the recent SFPA Expo in Atlanta,

Georgia. Pictured left to right are Ben and Vicki

Crim, and Malinda and David Richbourg. Ben

is Director of Engineering at Hood Industries,

Hattiesburg, MS, and David is General Manager

at Culp Lumber, New London, NC.

The car shown was displayed courtesy of Ken

Morgan of Morgan Lumber at Red Oak, VA. Ken

is an avid racing enthusiast, and now that he is

retired he has more time to pursue his passion

for race car driving.

Complimentary Subscription

Sign up today!THE MAGAZINE FROM USNR | ISSUE 1 - 2011

GOOD ROTATIONS

OUTSIDE THE CYLINDER

WEST FRASER MOVES TO VISION ON LHG

New primary lines at Carrier Lumber yield better rotation, recovery

BlockPLUS enhances performance at Rainier Veneer

Ramping up for a market turnaround

INSIDERMillwide

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Title

Company

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Tel. Fax

E-mail

Please (continue to) send me the Millwide Insider magazine by USNR.

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Fax to 250.804.4028 or mail to Colleen Schonheiter, USNR, PO Box 8, Salmon Arm, BC V1E 4N2. To unsubscribe, or to subscribe by e-mail, please send your request to [email protected].


32 SOLDIn 2010 USNR launched the Multi-Track Fence,

a cost effective solution to improve the speed

and accuracy of the trim line. The first fence was

installed in June 2010, and today 32 Multi-Track

Fences have been installed globally.

This fence accommodates very high speeds with

precise board positioning, an excellent choice for

high-speed optimized applications requiring 0.1”

(0.25 cm) positioning resolution. The Multi-Track

Fence allows wider lug spacing at high speeds,

with less critical timing than other rotary fence

models. It operates without any air or hydraulics;

all electric actuation.

Join the growing number of mills who are utilizing

its many features. To learn more contact your sales

representative, send us an email at [email protected]

or call 800-BUY-USNR today.

Multi-Track FenceWinninG dESiGn FOr HiGH SpEEd, LOW MaintEnancE and prEciSE pOSitiOninG

To see a video of this fence in action, go to

http://www.usnr.com/media/Multi-Track-Fence.wmv.

PO Box 310Woodland, WA 98674

2011nOv. 16–19Expocorma Concepcion, Chile

nOv. 29–dEc. 2WOOdEx Moscow, Russia

2012FEb. 8–9iHLa Indianapolis, Indiana

Mar. 1–2pELicE Atlanta, Georgia

Mar. 13–15KFia London, Kentucky

Mar. 14–16HMa New Orleans, Louisiana

Mar. 29–31austimber Mount Gambier, Australia

John Seifert is USNR

Regional Account Manager

based in the Northeast US.

John’s experience in this industry

spans nearly five decades, with

his primary focus being hardwood

processing. With tenure in both

sawmills and supplier companies,

John has seen it from both sides.

His exper tise has proven its

value for putting together the

right combination of technology

for his customers. “I’m proud to

contribute to the development of

hardwood optimization with the

MillExper t edger optimizer.” John

also contributes ideas for features

in carriage optimization.

John understands the frequent

ups and downs of business for

his customers. “Because my

customer base is made up of 99%

hardwood sawmills, it has been

challenging with the hardwood

market in its worst slump since

I star ted in 1963.” But that hasn’t

quelled his interest. He has been

active in sawfilers’ associations

for many years and has even

written two instruction manuals.

An avid spor tsman, John likes

to fish, hunt deer and squirrels

with his Brittany Spaniel, Rusty.

Having raised four grown children,

John and his wife, Cathy, now

enjoy many weekends camping.

Millwide INSIDER is printed on recycled paper.

upcOMinG EvEntS

PR

OFI

LE

seeing both sides - usnr

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