Smart Peel proves itself PLYVISIONS ­ Raute Customer Magazine Issue 6 Koskisen invests in the future Attention to moisture control! Lathe modernizations offer many benefits Raute Customer Magazine ­ December 2005 3 Contents A year of recovery and growth Proper moisture control yields positive results New vision technology at Olympic Panel Products Short news Smart Peel proves itself Lathe modernizations offer many benefits Koskisen invests in the future Fairs Appointments 3 4 8 12 13 16 19 22 23 "We do our best to provide you with the elements for profitable business; now and in the future." Nine new... ...Smart Peel lathes have been sold to customers in Europe, Asia and Africa. More about Smart Peel technology on pages 13­14. Did you know... ...that conversion to a laser-based geo-centering system will eliminate hard stops and mechanical contacts, resulting in improved performance and less maintenance? Details on page 18. PlyVisions is Raute Corporation's Customer Magazine. Editor-In-Chief: Molli Nyman, molli.nyman@raute.com Editorial Group: Matti Aho, Veli-Matti Lepistö, Rick Massey, Tapani Kiiski Layout: Onnion Oy Printing house: Libris Oy Address changes: tuija.leppanen@raute.com Publisher: Raute Corporation, P.O.Box 69, FI-15551 Nastola, Finland, Tel. +358 3 82 911, fax +358 3 829 3511, www.raute.com Copyright Raute Corporation. All rights reserved. Reproduction permitted only with permission from Raute Corporation. Cover photo: Ms Ding Yuchun. Photos by Raute if not mentioned otherwise. ISSN 1459-3165 >> from the CEO A year of Dear Reader, recovery and growth us to make improvements in our processes and to develop our network of partners. We will continue to learn and improve based on the lessons we have learned. In the fall we were fortunate in securing a major order comprising the bulk of machinery for a green field plywood mill to CMPC, a Chilean company based in Santiago. In addition to representing a significant order for Raute, the CMPC order serves as an indication of the trust in the future of the plywood industry. When a well-respected company like CMPC makes the decision to enter a new area of business, it is a good indication that similar business exists for other new producers as well. Thanks to the support of our customers, this will be a good year for Raute. Our recent successes also indicate that the areas on which we have decided to focus our skills, products and technology do indeed serve our customers' needs. The "Raute Formula" for success, which we launched at the Ligna Fair in Hannover, Germany during May has proven to be relevant to Raute and our customers. While it may be difficult to prove mathematically, it is true that (recovery + quality + productivity) x capacity does add up to profitable wood products production. In order to be able to assist our customers in implementing this formula, we have invested in developing our understanding of the production processes of the wood products industry. Many of our people are highly skilled plywood specialists and not only experts in manufacturing machinery. Further, our strategy of providing a full service and technology portfolio supports our capability of implementing the Raute Formula. I hope you will enjoy reading this issue of PlyVisions and that each of you finds something of interest and value. I wish you all success during the remainder of this year and into 2006 and thank you for the trust you have shown in Raute. We remain committed to providing you with the elements of successful business in the future. Tapani Kiiski, President and CEO I cannot help but have positive feelings as I am writing to you. Even though this year hasn't yet come to an end, I believe we can already say that, for most of us in the wood products industry, 2005 has been a successful year. Our customers have done well and, furthermore, prospects for the near future indicate this situation will continue. PAST PERFORMANCES AND THE FUTURE OUTLOOK appear to have given our customers the confidence to start investing once again. That, in turn, has created business opportunities and demand for Raute products. When competing for that business, our earlier investments and efforts in product and technology development have paid back in a positive way. Let's hope the positive market situation continues. Raute began the year in a positive fashion. Activity began picking up in 2004 and was carried over into 2005. For the first few months of this year our customers were mainly focused on smaller investments aimed at improving the performance of their existing production capacity. The main exception was Finnforest's decision to expand their LVL mill in Punkaharju, Finland. The commissioning of large-scale projects in Australia and Chile also kept our people busy through the first few months of the year. Recently, there has been a dramatic rise in dryer sales in North America, particularly in Western Canada and the US Pacific Northwest. During the first six months of this year Raute booked orders for close to ten drying lines. Energy efficiency, dry veneer quality and a reduction in emissions combined with industry leading camera grading technology have been the reasons behind Raute's success in securing these major projects. This past summer was probably the busiest in Raute's history. The delivery, installation and start-up of all the previously mentioned smaller projects took place from June to August. It was due to the strong commitment and effort of our people that we succeeded in delivering a record high volume of orders. Experience gained from these deliveries helped THE RAUTE FORMULA: (recovery + quality + productivity) x capacity = profitable production of wood products PLYVISIONS ­ Raute Customer Magazine 3 positive results Proper moisture control yields 4 PLYVISIONS ­ Raute Customer Magazine text: Rick Massey RAUTE'S RANGE OF MOISTURE ANALYZERS enable mills to carry out precise moisture control at critical points throughout production. Proper attention to moisture control improves recovery, quality and productivity, as well as emission control, glue utilization and energy consumption. Failure to properly control moisture in veneer will result in recovery losses, veneer quality issues and problems at the press. Why proper moisture control is important Proper moisture control is critical in the veneer production process. If the moisture content is too high the glue bond may be poor, resulting in delamination and press blows. If it is too low the veneer may become case hardened and the glue will not penetrate the veneer to form a proper bond. Dry veneer is stacked by visual grade and moisture content. Proper attention to this step in the process will yield positive results. For example, face sheets can have larger moisture pockets because much of the moisture will dissipate when the veneer comes into contact with the hot press platens. Higher levels of moisture are also acceptable at the edges of the core plies because it quickly dissipates during hot pressing. On the other hand moisture pockets are not acceptable in the inner plies because moisture is not expelled properly during hot pressing, leading to poor glue bonds and press blows. Proper moisture analysis technology, together with a properly implemented moisture control strategy will produce the best plywood production results. is used to classify veneer into moisture classes, the number of which will vary depending on species and the dictates of the mill. Moisture classification ensures that the moisture range of each load of veneer is as narrow as possible so that loads with similar moisture content are dried simultaneously. This reduces redry and improves the quality of the veneer. The GMA's moisture clip function improves veneer recovery by clipping veneer to a width that is proportional to the amount by which it will shrink during drying. A feature that improves stack quality is the sheet weight function. The moisture analyzer can be set up to provide a signal, which controls the timing of the knock-off arms in the stacker to compensate for the weight of the sheet. Square stacks lessen the risk of damage to veneer sheets and improve the dryer feeding operation. DMA "Cross Tipple" moisture analyzer This moisture analyzer is installed at the dryer outfeed conveyor. Software determines if the veneer falls within mill-specified moisture parameters. If too wet, veneer is marked with a single ink mark. The unit can be tuned to each species and moisture level and used with all veneer sizes. To ensure that moisture data is gathered over 100% of the veneer's surface and that there are no "dead zones", contact brushes are arranged in a triangulated measuring configuration (Diagram 1). In addition, there is moisture trending of each brush, which indicates the dryer's ability to dry uniformly across its width while revealing possible prob- Diagram 1: Triangulated measuring configuration 0 1 500 VAC Controlling moisture in green veneer Raute's Green Veneer Moisture Analyzer (GMA) measures moisture in green veneer at 300 m/min (1,000 fpm). This data 3 000 VAC << The contact brushes are installed in a triangulated measuring configuration to ensure 100% coverage of the veneer and prevent any "dead zones". PLYVISIONS ­ Raute Customer Magazine 5 >> DMA cross tipple moisture analyzer seen here processing random veneer. lem areas within the dryer. Areas of high moisture occurring consistently could be an indication that the hot air flow is restricted and attention is required. which limit unnecessary redry and enable proper calibration for varying veneer thicknesses. Raute offers this as an optional feature DMA "Dry Chain" moisture analyzer This moisture analyzer is installed in front of the dry veneer stacker. It enables moisture pockets to be visually identified using a feature called moisture mapping, which is also available on the DMA Cross Tipple. Moisture data includes the average, peak and combined moisture levels, moisture trending for each brush, moisture history statistics and statistical dryer monitoring data. Another feature is moisture limit setting (Diagram 2), which enables moisture limits to be set for different areas of the veneer sheet. Moisture analyzers are also equipped with temperature compensation sensors, Using moisture data to control dryer speed Dryer speed is determined by veneer moisture content and the amount of time on both models of moisture analyzer. adjustable area Diagram 2: Moisture limit setting top 10% adjustable area center 8% bottom 10% 6 PLYVISIONS ­ Raute Customer Magazine right 12% left 12% >> measurable benefits MOISTURE METER FUNCTION Moisture classification MODEL GMA MEASURABLE BENEFIT Classifies green veneer into moisture classes to improve drying efficiency. Prevents over/under drying, reduces redry. Determines moisture content relative to shrinkage during drying. Veneer is clipped to width accordingly. Improves recovery. Adjusts knock-off according to weight of green veneer. Improves stack quality. Measures measure moisture content in the direction of grain. Data can be used to automatically control dryer speed. Indicates uniformity of drying across the width of the dryer in order to reveal areas of poor hot air flow. Ensures that moisture data is obtained over 100% of the veneer's surface and there are no "dead zones". Identifies moisture pockets, reduces press blows and helps ensures proper glue bond. Enables moisture limits to be set for different areas of the veneer sheet. Enables drying to a higher moisture content and improves press efficiency. Provides a visual map of the moisture level over the sheet of veneer. Continuously recurring areas of high moisture may indicate problems within the dryer. Saves space, provides precise dry end control and monitoring. Moisture clipping function GMA Sheet weight function GMA Dry veneer moisture content DMA cross tipple Moisture trending function DMA cross tipple Triangulated measuring Both DMA models Identifying moisture pockets DMA dry chain Moisture limit setting DMA cross grain Moisture mapping Both DMA models Combining veneer defect analysis and veneer moisture analysis VDA/DMA required to dry the veneer to its desired level. It is typically determined by measuring moisture before and after the dryer. Trial and error, together with empirical drying data, provide the dryer operator with correct speed setting data. Precise moisture data, however, enables dryer speed to be set automatically with a signal from the moisture analyzer. Raute offers this as an optional feature on both models of moisture analyzer. >> DMA screen displays moisture map, moisture distribution chart and moisture trend data. Combining visual and moisture grading Raute has combined the visual grading capabilities of the Veneer Defect Analyzer and the moisture analysis capabilities of the Dry Veneer Moisture Analyzer into a single unit. This sophisticated unit provides an open platform for setting individual visual and moisture grading parameters. It is installed in front of the dry stacker and provides mill management with unparalleled dry end process management control. >> DMA dryer speed control screen: Black: dryer speed, Red: peak moisture, Blue: average moisture, Green: veneer temperature PLYVISIONS ­ Raute Customer Magazine 7 New vision technology at Olympic Panel Products IN APRIL, 2003 ATLAS HOLDINGS LLC OF GREENWICH, CONNECTICUT acquired Simpson Timber's plywood and overlaying operation in Shelton, Washington, resulting in the creation of Olympic Panel Products LLC, the single largest plywood overlay facility in the world and the overlaid panel market leader in North America. 8 PLYVISIONS ­ Raute Customer Magazine >> New 10-bin dry veneer stacking system complete with VDA G3 grader and integrated dry veneer moisture analyzer installed on the #2 dryer line. In the background can be seen the original VDA installed in 1999 ahead of the first dry stacking system sold by Raute back in 1984. text: Rick Massey ACCORDING TO OPP's Manager of Technology and Product Development, Ken Pratt, little investment had been made at the mill since installation of a Raute-Mecano VDA G1 camera grader in May, 2000. "At the time of the acquisition the new owners confirmed their commitment to the mill and wanted to know which areas of production required the most immediate attention. They were told it was dry veneer grading and stacking", said Mr. Pratt. Purchase of a new Raute 10-bin dry stacking system, complete with a VDA G3 veneer grading and roughness analyzer and integrated DMA dry veneer moisture analyzer followed. The new equipment, installed on #2 dryer line, was completed in October, 2004. At the same time that installation of the new equipment was proceeding, the mill's existing 10-bin stacker, installed in 1984 on #4 dryer line, got an upgraded VDA equipped with a veneer roughness detector and moisture analyzer, as well as new controls. © Panel world © Panel World Roughness analysis critical to quality Prior to making their decision to buy the new dry veneer grading and stacking system from Raute, OPP management benchmarked a number of existing installations. "Benchmarking gave us the confidence to proceed with the purchase from Raute", said Mr. Pratt. "We were very impressed in particular with the quality of the stacks we saw at a mill in Canada that produces dried veneer for PLYVISIONS ­ Raute Customer Magazine 9 © Panel World >> OPP management, from left: Jim Zmudka, Sales and Marketing Manager; Jim Langenberg, Plant Manager; Ken Pratt, Product Development and Process Control Manager; Art McCullough, Maintenance Superintendent; Fran Eck, General Manager; and Morgan Stein, Plant Controller. export. Plus, our prior experience with Raute's service organization had been very satisfactory and we had long relied on their system's ability to analyze veneer roughness, something their competitors weren't able to offer." At OPP, sheet placement accuracy with the new stacker is 3/8" (10 mm). Mr. Pratt noted that being able to generate accurate roughness data is very important to the mill for a number of reasons. "By having reliable roughness data, we can see how well the lathe is performing. It also helps to ensure that veneers are correctly dispersed throughout the layup and that we have the correct face sheets to ensure proper bonding of the overlay material, which includes minimizing telegraphing through the surface." formance for moisture, roughness and grade determination", said Mr. Pratt. Moisture control impresses Mr. Pratt was particularly impressed with the performance of Raute's DMA dry veneer moisture analyzer, which he stated has performed at a particularly high level. "Moisture control is very important and with the Raute system we are able to analyze moisture content with a high degree of precision", he said, adding, "From November through the end of January it can be difficult to have tight control over moisture in the wood. The veneer is cold, more difficult to glue, may be covered with wet tarps and is often purchased from outside sources." Mill management stated that between November 2003 and February 2004 it operated at a level of 1.0% press blows. For the same period during 2004/2005, following installation of the new VDA/DMA, press blows fell to 0.5%. The mill had expected a drop of about 0.1%. The Dry Veneer Moisture Analyzer, with its proprietary triangulated brush configuration, provides 100% coverage of the surface of the veneer sheet for moisture analysis pur- 98% on-grade performance The performance of the Raute dry veneer stacking system has, according to mill management, met OPP's expectations. "We have been very satisfied with the performance of the stacking systems themselves and with the moisture analyzers and camera graders in particular. As a result of our own efforts and with the support of Raute, we have calibrated the system to the point where we enjoy 98% on-grade per- << The new dry veneer stacker has provided a new level of efficiency and quality to Olympic Panel's dry end operations. >> New 10-bin dry veneer stacking system complete with VDA G3 grader and integrated dry veneer moisture analyzer installed on the #2 dryer line. 10 PLYVISIONS ­ Raute Customer Magazine "We have calibrated the system to the point where we enjoy If you put in the time up front, you will enjoy the benefits." 98% on-grade performance for moisture, roughness and grade determination." A solid investment For Olympic Panel Products, the decision to install a Raute dry veneer grading and stacking system has proven to be a good one. According to Ken Pratt, overall grade has improved 4­6% for the whole mill since the VDA G3 was installed. Add to that the decrease in press blows made possible through better moisture control and improved roughness detection and the result has been very satisfactory. "The Raute dry veneer stacking system with integrated grading, roughness detection and moisture analysis has proven to be a solid investment, one that would be particularly important to mills producing value-added products, like Olympic Panel Products", stated Mr. Pratt. poses. The mill no longer gets dry veneer mixed in with wet and can comfortably grade moisture down to 3­4%. VDA provides valuable data When asked to comment about the overall performance of the new line, Mr. Pratt was complimentary. "There are many features that make the performance of our new VDA veneer grader stand out. The illumination system for one is significantly better than on the original version. It provides stable intensity over a long period and we have no complaints from our downstream customers within our own mill production environment. Everybody receives the veneer in the condition it should be received." "You have to understand that the VDA G3 makes black and white grading decisions with respect to defect recognition. It won't err on the side of caution and so will always make the right grading decision, provided it is set up properly. In this case, sufficient attention was paid to setting up the parameters correctly and so we have been able to enjoy a high level of performance and positive results." Mr. Pratt also sees benefit in the various grading scenarios offered by the system. "The `What If?' grading scenario enables us to optimize our grade mix to satisfy both industry standards and to meet some proprietary requests from customers. For example, if the specification calls for 1½" knot, and the customer wants a 2" knot, the VDA instantly shows the percentage of veneer that would have yielded the larger knot. It performs its tasks in real time and so does not hamper production. It is also very useful for product development purposes." Another useful feature, according to Mr. Pratt, is the `Critical Defect', which identifies where the mill is losing grade. "If we see a trend in the critical defect, we are able to adjust accordingly. However, it is necessary to work closely with the vendor in order to determine and control all these different scenarios. >> facts RAUTE HAS BEEN A LONG-TIME SUPPLIER of technology to Olympic Panel Products, beginning in 1984 with the installation of the first automatic dry veneer stacker to be sold in North America. Two years later, Raute installed a 24-opening overlay line. Other investments include rotary clippers, multi-bin green stackers for both full and half sheets, a 14-section roller jet dryer, an 8 ft. veneer composer and a polypatch line. Improvements made at OPP, together with the Quality Operating Models and other production initiatives implemented by the company, have seen production grow from 90,000 m3 (100 MM3/8) to 140,000 m3 (160 MM3/8) in the first two years under new ownership. PLYVISIONS ­ Raute Customer Magazine 11 >> short news text: Matti Aho Raute diversifies into sliced veneer technology RAUTE HAS ENTERED the sliced veneer machinery business by acquiring the technology of the Italian company Intercomer srl. The purchased technology includes veneer slicing, drying and clipping machinery and equipment. With this acquisition, Raute plans to expand its interests in the global wood products business, which presently encompasses rotary peeled veneer and plywood, laminated veneer lumber (LVL), engineered wood flooring and panel overlaying. Slicing is one of the three major methods of cutting decorative veneers. The others are rotary peeling and halfround (staylog) slicing. These methods produce veneers with different visual characteristics. Making veneer is the most decorative and most economical way of producing high quality surfaces of real wood: 700­1,000 square meters of decorative veneer can be made of one cubic meter of wood. Decorative veneers are commonly used in wall and door paneling, furniture and cabinets, flooring and profile-wrapped moldings. 700­1,000 square meters of decorative veneer can be made of one cubic meter of wood. text: Molli Nyman CMPC chooses Raute technology for its new plywood venture EMPRESAS CMPC S.A. IS A GIANT in the South American forest products business. With over 80 years of experience, CMPC produces sawn lumber, pulp and paper, tissue, and cardboard. It perhaps comes as no surprise then that the company recently announced they are diversifying into the panel industry with construction a 250,000 m3/a plywood mill to be built in Chile. The raw material for the new mill will be Radiata pine grown on CMPC's own plantations. Raute has been selected as the principal supplier of machinery to the new mill, which will include all machinery and equipment from the peeling lines through panel pressing. The announcement by CMPC management of their plans to enter the plywood business comes soon after start-up was completed at the new Arauco Radiata pine plywood mill in Nueva Aldea, Chile. This was the third complete plywood production line delivered by Raute to Arauco. In the case of both CMPC and Arauco, management cited versatile and modern technology as being critical factors behind their decision to choose Raute. Raute technology has proven itself to be second to none in optimizing raw material recovery, minimizing labour utilization, producing high-quality products and minimizing energy consumption. Another decisive factor was Raute's extensive list of global plywood references, many involving complete mill-wide projects undertaken in demanding environments. Once in production, the mill will produce high-quality sanded panels for sale in the United States and Europe. Plywood will become a value-added addition to the already impressive CMPC product range and will complement the company's lumber production in the building products sector. Delivery of equipment is scheduled to begin in May 2006 with start-up later that year. >> Raute and CMPC management closing the plywood mill deal. 12 PLYVISIONS ­ Raute Customer Magazine Smart Peel text: Rick Massey proves itself Raute launched the Smart Peel Concept at Ligna 2003. Since then, nine Smart Peel lathes have been sold to customers in Europe, Asia and Africa and interest in all markets remains strong. SMART PEEL IS A COMMON PEELING PLATFORM that adapts to the specific needs of the various peeling parameters production requirements in In all cases, however, Smart at a high level of recovery. veneer and plywood producer. Its can be configured to suit specific terms of species and productivity. Peel produces high-quality veneer PLYVISIONS ­ Raute Customer Magazine 13 PEELING PARAMETER Laser curtain block centering SMART PEEL ADVANTAGE More full sheets Less random High volume recovery Elimination of carriage skew Elimination of carriage travel lag Positive contact with the block Elimination of knife chatter Smoother veneer Improved veneer thickness tolerance Improved spindle speed control Precise ramp up/ramp down Precise contact of knife with the block Precise knife positioning increases recovery Proper veneer checking Stronger veneer Smooth surface Overall high-quality veneer User friendly The machine-operator interface is especially user-friendly, with all important peeling parameters ­ pitch angle curves, spindle pressures and peeling speeds ­ being menu-driven. Those peeling functions most often utilized are conveniently available through the operator joystick. The operator may override the fully-automatic peeling operation at any time. The peeling operation is displayed in real time as are specific interruptions and their cause. All reporting relevant to the peeling operation is accessible through Raute's millwide Management Information System. Knife carriage feed Knife gap adjustment Drive and positioning control Digital pitch angle control Smart Peel uses the concept of Optimal Peeling Geometry (OPG), which synchronizes all the critical peeling parameters. The results are fewer spin-outs, greatly improved veneer thickness tolerance control and overall higher quality veneer. These benefits are especially noticeable when peeling juvenile wood or blocks of marginal quality. What's more, Smart Peel is able to achieve these results regardless of the productivity demands of the mill. Consider upgrading Many of the unique features of the Smart Peel Concept are available as upgrades to existing lathes, regardless of their manufacturer. Raute has undertaken upgrade projects involving carriage replacement, installation of laser curtain scanning, spindle retrofit and controls modernizations, to name a few. In every case, Raute has worked with mill management to work out an upgrade schedule that causes the least interruption to production. Read more about lathe modernizations on pages 16­18. Optimal peeling geometry The peeling geometry utilized in Smart Peel is unique to this product from Raute. In designing Smart Peel, Raute's engineers turned away from the traditional fixed back-up roll concept, opting instead for 5-point rotation and 3-point support of the block during rotation. This control is provided by the two driven spindle assemblies, two driven backup rolls and the roller or flat nose bar. When combined with the multi-step spindle retraction of the dual or triple spindles, the result is precise control of the block from round-up to core drop. Digital carriage feed is another feature of Smart Peel's peeling geometry. By driving the carriage from a single power source, skew is eliminated and knife posiIN JUNE, 2004 Raute signed a contract with tioning is maintained under positive conthe Chinese Genhe Forest Bureau for the trol. Vibration, a frequent cause of poor purchase of a complete Smart Peel lathe veneer surface quality, is also eliminated. line. CIMC, the company in Inner MongoVeneer quality is enhanced by the lia that will operate the line, is the world's use of digital pitch angle control, which largest producer of sea containers. >> CIMC and Chinese Genhe Forest assists in creating the correct angle and Following a review of Raute's peeling Bureau representatives checking technology and global references, repdegree of veneer checking. This ensures veneer quality at test runs resentatives of CIMC were satisfied that that the veneer lays flat on the conveyor at Raute's Nastola workshop. Raute's Smart Peel was the correct techand does not break during subsequent nology for processing their larch and birch blocks. The line processes 160­500 mm handling. It is especially important diameter blocks and consists of a block feeder and linear loader, Smart Scan curtain during drying as veneer that is heavily laser XY optimizer and charger, Smart Peel lathe, clipping trash gate, two tray catchchecked will tend to fracture and break. up conveyor, clipper scanner, moisture analyzer, rotary clipper and three-bin green It also ensures that the surface veneers veneer stacker. The line was fully assembled and tested with the customer's representatives present at Raute's Nastola workshop in Finland during April 2005. Commiswill remain intact and assures the oversioning began in October of this year. all integrity of the plywood panel. >> case Genhe 14 PLYVISIONS ­ Raute Customer Magazine French impressions of the Smart Peel Raute's representative Christian Lallia made a brief interview with Mr. Xavier Hardy, the Managing Director of R. Drouin S.A. in France, about their first experiences with their new peeling line. One of the latest Smart Peel lathes was delivered to R. Drouin. When was the decision taken to purchase a new peeling line? The decision was taken in 2003. Why did R. Drouin need a new peeling line? We needed to replace an old Peeling line with new one capable of peeling small diameter blocks up to 3,2 m. What products are produced at your mill? Plywood and special industrial packaging, machined to special purposes. What species do you process and what is the annual production of your mill? We work on the Smart Peel line with 100% Poplar. Our total annual production is 11 000 m3. We are specialized on the European, especially the French market. More information on R. Drouin can be found at www.drouin.fr. What is your impression of Raute, its people and products? We were quite impressed with Raute's activity, flexibility and that they took our requests seriously during the whole process. We were satisfied both with the people and the technology. What is unique or special about R. Drouin's products? The great range of small orders is challenging. The key words are tailor made. What were your main targets when buying the new lathe? Need to improve recovery, increase productivity and improve quality? We needed flexibility, ability to peel longer blocks up to 3,2 m, and we wanted to double the productivity. How have you been able to reach the targets so far? The recov- >> One of the latest Smart Peel lathes was delivered to R. Drouin in France. Mr. Christian Lallia and Mr. Jarkko Kaislaoja from Raute are witnessing the start-up of the line with Mr. Xavier Hardy, Managing Director of R. Drouin S.A. ery has improved, we have significantly less random. At this point we cannot tell more, as the line is not yet fully commissioned. Were there any additional benefits from the new lathe? Yes, less composing and the lathe knives last longer than before. How did you find the the installation and start-up. Was Raute able to satisfy your needs in this respect? The installation went smoothly but the commissioning has taken longer than expected. In general, though, we are satisfied with the purchase of the Smart Peel lathe and with Raute. Raute's Smart Peel deliveries Year 2005 2005 2005 2005 2005 2005 2005 2004 Company CMPC (2 units) CIMC International Korindo Tawau Plywood Fankom SA Plywood R. Drouin Latvijas Finieris Country Chile China Indonesia Malaysia Russia South Africa France Latvia Species Plantation pine (Radiata) Larch, birch Plantation species Plantation species Birch Plantation pine Poplar Birch >> Smart Scan XY curtain laser improves recovery PLYVISIONS ­ Raute Customer Magazine 15 >> Smart Scan XY+ and SPC powered back-up rolls are available as modernizations to the old VS lathes and XY-chargers. New Optimal Peeling Geometry ensures less spin-outs and higher veneer strength. A Smart Scan modernization, consisting of curtain laser sensors and optimizing spindles, improves raw material recovery and productivity. Lathe modernizations offer many benefits Tailor-made solutions to suit mill needs The table on page 18 shows the range of upgrade options available from Raute and the intended benefits. Market demands and production factors will determine if it would be beneficial to carry out the work in stages or to shut down the line entirely while the work is undertaken. Mills, too, don't want the restrictions imposed by proprietary controls, preferring to use off-the-shelf components and not having to pay service charges every time changes need to be made to the lathe's control functions. The use of advanced monitoring and tuning tools, many of which can be accessed over the Internet, enable quick and inexpensive access to the lathe. Transparent controls and open communication standards mean that mills are not dealing with "black box technology", such as has been the case with previous control systems, like VME. For mills wanting to improve the performance of their peeling operation, Raute provides a modernization package that will enable older lathes to perform at a more productive level. Similar upgrades are available for scanning and clipper control, stacking and tray controls. LATHE MODERNIZATIONS cover mechanics, hydraulics and controls and are carried out by qualified Raute service technicians. The scope of the work depends on the condition of existing equipment, production needs, and the ability of the line to handle material downstream. In every modernization project, a work schedule is developed that least disrupts the mill's production schedule. Measurable benefits The measurable benefits of having Raute modernize your lathe will be realized in the areas of productivity, recovery, quality and capacity. With respect to productivity, effective operational time increases because maintenance is reduced. Maintenance activities that previously took hours can be accomplished in significantly less time, such as changing out chucks or repairing spindles. The Smart Scan XY laser curtain also improves productivity Open platform controls Raute offers an open lathe control platform, which enables mill personnel to have greater flexibility over production. 16 PLYVISIONS ­ Raute Customer Magazine >> Behind the controls of a modernized lathe. >> a planned approach THE LATHE PLAYS A CRITICAL ROLE because that is where the standard of quality begins. Poor results at the lathe will result in poor results further along the process. That's why a planned approach to modernizing your lathe is required. The various stages of a typical lathe modernization project are: Preparation of a detailed schedule covering the project design period, during which the scope is defined, technical issues are agreed upon and drawings are produced. 1. 2. 3. 4. The pre-project period, during which electrical work is carried out and equipment is delivered. by ensuring that more usable veneer, both full sheets and random, is recovered at the lathe and at the clipper. Recovery benefits are also significant. Laser curtain scanning improves veneer recovery by as much as 4%, while increasing the number of full sheets and wide randoms. A clipping trash gate will improve recovery by eliminating leading edge taper and sheet break. Small spindles enable the lathe to peel down to a 63 mm (2½") diameter core, while digital pitch angle adjustment reduces roll-up and helps produce smooth peel down to core drop. A well-executed lathe modernization will also improve veneer quality. Over time, lathe components wear, which can lead to thick/thin veneer and surface roughness. The better the quality of the veneer, the better it will withstand subsequent operations in the manufacturing process. It will dry better (won't break in the process due to over checking); lay up better (remains intact during automatic or manual handling); glue better (better glue spread control, less chance of delamination in the press); press better (good peel tolerances mean that panels are not over-compressed in the hot press); and sand better. Overall, the quality improves and the value of the panel increases, together with the reputation of the producer. And, finally, the mill will operate at or above capacity, which will have a positive affect on profitability. What's more, when market conditions dictate, the capacity can be ramped up to take advantage of higher prices, which further improves the return on investment. The shutdown period, during which the lathe goes off-line, the mechanical elements are installed, additional maintenance is carried out and operator training is undertaken. Check-points, during which testing and acceptance is completed. This planning ensures that the modernization is completed on time with the least disruption to production. It must be remembered, however, that even the most thorough inspection ahead of time may not detect certain problems with the inner workings of the lathe. Careful planning will, however, help to mitigate these problems. the quality improves and the value of the panel increases, together with the reputation of the producer. PLYVISIONS ­ Raute Customer Magazine Overall, 17 >> tailor-made solutions to suit mill needs MODERNIZATION ITEM Improved log lifts BENEFIT · More robust, less prone to contamination · Less maintenance and downtime · One-step XY feed and positioning · Fewer wear items, faster operation · True 3D block imaging · Higher recovery and capacity · Optimizes knife carriage positioning · Enables carriage to run in auto-mode · Less carriage travel ­ higher throughput · No risk of collision between charger transfer arms and spindles · More reliable; no separate damping · No need to retract carriage after round-up · Raises throughput by 1 second per block · Eliminates leading edge taper · Better recovery, higher production · Greater reliability · Easier to follow run-time data · More user-friendly controls · More accurate, faster positioning · More accessible programming · More efficient production · Progressive veneer thickness regulation · 50% reduction in thickness deviation · Less maintenance · Greater positioning accuracy · Smoother, faster carriage travel · Elimination of carriage skew ­ stronger veneer, better recovery · Eliminates backlash · Provides improved knife gap control · Ensures smaller thickness variation · Faster change-out · Need only replace damaged end · Chucks screw onto end of spindle · Simplified · Less maintenance · Better performance · Open access to bearings · No need to remove cylinders · Better recovery with smaller core · Reduction in spin-outs · Higher recovery due to fewer spin-outs and peeling to a small core · Higher knife gap compression rate · Improved veneer thickness tolerance · Greater veneer strength · Ensures that the veneer is peeled at the optimal angle needed to produce high-quality veneer · Ensures that optimal peeling forces compensate for knife wear · Eliminates hard stops, mechanical contacts · More accurate geo-centering · Less maintenance Linear loader c/w laser prepositioning Block charging including new Smart Scan XY laser curtain and optional motion control Clipping trash gate with hydraulic cylinders and improved geometry Advanced automation incorporating data collection and production management Improved motion control Intelligent PLC Improve the efficiency of the knife carriage feed by upgrading to planetary roller screws plus knife gap regulator Addition of AC-motor and servo control New style progressive knife gap adjustment 2-piece spindles Hydraulic circuitry Split spindle housing Triple spindles Full-length powered or idling backup rolls with Optimal Peeling Geometry (OPG) and position/pressure control Improved pitch angle control with preset curve options, offset fine tuning, editor and position control Laser geo-centering 18 PLYVISIONS ­ Raute Customer Magazine plywood The Finnish company Koskisen Oy produces specialty plywood for the construction, furniture and transportation industries worldwide. The company's commercial activities include wood procurement, sawmilling, plywood and particleboard production, and prefabricated wooden houses. Founded in 1931, control of the company remains with the Koskinen family. AT THE COMPANY'S PLYWOOD MILL 100 kms north of Helsinki, Finland, Koskisen produces over-sized specialty panels that fill an important market niche and help differentiate Koskisen from their competition. The decision by Koskisen to begin production of over-sized birch plywood was made at the start of 2000. VT2000 (Veneer Technology 2000) was chosen as the working title for the development project and soon after the project was launched, Koskisen began investing in new machinery and process equipment. Phase I of VT2000 was aimed at satisfying management's goal of producing panels larger than their traditional 1,500 mm x 3,000 mm (60" x 120"). At the same time, annual capacity was to be increased to 80,000 m3 annually (90 MM3/8). The investment was aimed at handling 2,000 mm-wide veneer (79") and included block handling equipment; a peeling line from lathe to stacker; a drying line complete with camera grader and dry veneer stacker; panel layup and pressing, and panel handling lines. During the planning and development phases of the VT2000 project, Koskisen worked closely with Raute, whose principal engineering and manufacturing facilities are located within an hour's drive of Koskisen's mill. >> Repairing of high quality large-dimensioned plywood. The operator has easy access to the whole panel. Koskisen invests in the future of specialty VT2000 (Veneer Technology 2000) was chosen as the working title for the development project. PLYVISIONS ­ Raute Customer Magazine 19 The whole process is designed to meet the capacity needs of the mill while satisfying the QC requirements of the end-product with respect to surface and edge quality. Panel handling plays a significant role Following the successful completion of Phase I, Koskisen moved into Phase II, which was concluded during 2005. This saw additional capacity being added, as well as a new production facility. Of significance were the new panel sawing, sanding and repair lines. Delivered by Raute's Jyväskylä division, the deliveries represent the latest in panel handling technology and have helped Koskisen realize its goal to produce oversized panels. The delivery also ensures that the capacity of the production lines previously delivered by Raute are fully utilized as well helping the customer satisfy the continuously tightening quality and size requirements of the wood-based panel market. The panel saw line is designed for high-speed, automatic set-up of the panel feeder, trim saws and stacker and is able to handle a variety of sizes. Consideration has been given to minimizing downtime during product changeover in order to maintain high productivity and line capacity. The height of the saw blade is adjusted automatically according to the thickness of the panel and set at the optimal position required to achieve the best possible sawing quality and accuracy. Handling of the panel is done without sudden or harsh impact to ensure that panel edges and surfaces are not damaged. The panel repair line offers fast, automatic set-up of the panel feeder and stacker. It, too, is designed to minimize downtime during changeover from one product to another in order to maintain high productivity. The line can process a range of panel sizes. Special attention has been paid to the ergonomics of the system to ensure that the operators are able to perform their tasks without physical stress. The panel sanding line also provides fast and automatic panel handling. Stacks are loaded onto a powered infeed rollcase and conveyed to a lift hoist. They are then transferred by suction feeder onto an alignment conveyor ahead of the first of two Steinemann wide-belt sanders. Manual QC can be undertaken between the first and second sander. The whole process is designed to meet the capacity needs of the mill while >> The panel feeding and stacking equipment is automatically adjusted by the production planning system (ERP) to the required panel sizes. 20 PLYVISIONS ­ Raute Customer Magazine >> The saw blade height position is automatically adjusted according to the panel thickness, which guarantees optimal sawing accuracy. satisfying the QC requirements of the end-product with respect to surface and edge quality. Products geared to export Of its total plywood production, Koskisen exports 85% and 15% being sold at home. Koskisen maintains close contact with its customers through a network of sales offices in Germany, the United States, France, Great Britain, the Netherlands, Sweden and Poland. Company management believes that their corporate structure and close proximity to the markets they serve makes it possible for Koskisen to respond faster than their competition and provides them with a competitive edge. A successful conclusion With the successful conclusion of the VT2000 initiative, Koskisen today produces 100,000 m3 (110 MM3/8) of birch plywood annually, 80% of which is overlaid with phenolic films or other materials, including the new over-sized panels. >> The operator of the sanding line monitors and controls the line's operation. PLYVISIONS ­ Raute Customer Magazine 21 >> fairs Raute maximizes its performance at Ligna+ LIGNA+, THE WOOD PRODUCTS INDUSTRY'S LARGEST FAIR was once again held this past May in Hannover, Germany. As in past years it succeeded in attracting tens of thousands of wood products professionals. Raute exhibited in Hall 27 and once again our stand proved to be a popular gathering place for a large number of fair attendees. At this year's event, the focus of Raute's participation was "Maximized performance ­ profitable production". It was the task of our sales staff to demonstrate how Raute's technology and services assist customers in improving raw material recovery, raising productivity, optimizing quality and increasing the capacity of their production processes. In other words ­ how to create a competitive advantage. Special emphasis was put on the Smart Peel lathe, with visitors being able to see the lathe in action via a specially constructed Lathe Operator's booth, which was installed at our stand. This virtual tour of a highly modern and smart peeling process was not only informative but also provided an element of fun. A customer seminar was also arranged in connection with the fair, the theme of which was how to maximize and optimize performance by focusing on the things that matter most: recovery, quality and productivity. Raute staff on hand were pleased to meet almost 100 participants from all over the world. We look forward to again participating at Ligna+ 2007. >> 22­24 March come and meet Raute at: in 2006 Woodtech in Portland, Oregon, USA 27­30 June WoodMac in Shanghai, China 11­15 September Lesdrevmash in Moscow, Russia 22 PLYVISIONS ­ Raute Customer Magazine >> appointments Raute strengthens sales expertise in Europe RAUTE HAS APPOINTED AN AGENT to service the plywood and veneer industries in Germany, Switzerland, Belgium and Austria. Mr. Karl Alberts, former manager of Raute GmbH and an old friend to the plywood industry in the German-speaking regions of Europe, brings many years of experience to his appointment, which became effective in October, 2005. In the course of his extensive career in wood products, Karl has been involved in all areas of the rotary and sliced veneer markets. A qualified machine mechanic, Karl holds a degree in mechanical engineering, which has provided him with a professional understanding of the plywood and veneer manufacturing processes. When asked about his views on plywood manufacturing in central Europe, Karl stated that, although a number of companies in his sales territory have established branches in Eastern Europe, there is still a strong core of manufacturers in central Europe that will continue to invest in new machinery and production lines. Karl is well qualified to speak on matters related to the central European market. During the twelve years in which he previously served the plywood and veneer market on behalf of Raute, he was successful in placing a significant amount of Raute technology into mills including XY block optimization and charging systems, complete peeling and drying lines, and press systems. Karl sees future investments in his sales territory as concentrating mostly on the modernization of existing equipment in order to improve raw material recovery, maintain and improve quality and raise overall productivity and capacity of the mills. With this in mind, he believes there is excellent opportunity to sell Raute technology, which offers improvements in these areas as well as those that reduce labour costs. Such products include XY systems based on laser curtain technology, veneer camera graders, smart composing lines, automatic veneer patchers, and efficient panel handling systems, to name a few. Karl believes that this focus, together with Raute's proven solutions, will provide his customers with their best opportunity for successful growth in a competitive market. In addition, Karl sees investments in value-added manufacturing, such as film-faced overlaying, as offering significant opportunity for the growth of his customers' businesses. Karl will be spending the next few months renewing his many contacts as well as introducing himself to those who have come into the industry during his absence. "After many years working with Raute and a lot of good experiences and cooperation with former colleagues, I'm happy to be back and to continue this good cooperation." Karl Alberts can be contacted at: Am Forsthaus 46, D-49477 Ibbenbüren, Germany. Phone: +49 5451 23700, mobile: +49 5451 78512, karl.alberts@t-online.de Enhancing sales forces for Russia and the CIS countries WE ARE PLEASED TO WELCOME Mr. Mikko Vanhanen, our new Area Sales Manager for Russia and the CIS countries. Prior to joining Raute, Mr. Vanhanen held a similar position at Loglift Jonsered Oy Ab. Mikko Vanhanen can be contacted at Raute's Nastola office: Tel. +358 (0)3 82 911, direct +358 (0)3 829 3335, mobile +358 (0)400 173 979, fax +358 (0)3 829 3511, mikko.vanhanen@raute.com PLYVISIONS ­ Raute Customer Magazine 23 Global expertise in wood products technology Raute is the leading technology company in its sector serving the wood products industry worldwide by adding value to its customers' business. The core of operations comprises the manufacturing processes for veneerbased products. Jyväskylä Nastola Kajaani St. Petersburg Moscow New Westminster, BC Beaverton, OR Rossville, TN Beijing Singapore Jakarta Santiago Raute Agent www.raute.com