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This provides an overview of recently completed FIEA technology events. It will provide a summary of the technology programme, comments from those attending and participating, links to any proceedings, training or troubleshooting resources, follow-up activities planned as a consequence of the programme and images of those attending and participating. Jump to an event on this page:
Programme Resources
FIEA members can download a number of selected papers from the events, directly from the members technology updates section on the web site.
Programme Summary
Programme Summary
Programme Summary Wood Manufacturing 2007 was a series of practical workshops and managed exhibitions that ran for New Zealand and Australian wood manufacturers in March and April 2007. Close to 200 delegates attended the two technology programmes. In addition to key Australasian expertise, international expertise from Germany, Italy, USA, Canada, Sweden and Norway participated in this series. Limited copies of the conference proceedings are still available from FIEA offices. Programme Images
Programme Summary Over 120 wood producers met at DryTech 2006. New timber drying practices, tools and technologies being employed by leading Australian, New Zealand, US, Canadian, European and Chilean wood producers were outlined. Major advances included in-line moisture content measurement of green and dry lumber for segregation, new innovations for air flows to reduce moisture variability from temperature changes through the dried timber, improved conditioning systems and post sorting of lumber at the planer. New drying schedules, new kiln designs and results from recent research were outlined through a series of practical workshops, displays and industry focus groups. At both events, environmental impacts, including emission restrictions was seen to be an emerging issue for the industry over the next decade. The importance of restrictions being imposed on emissions from timber drying operations by local councils and expectations of consumers for products being processed in a way that minimises the environmental impact was seen in the array of new kiln designs and technologies that were discussed at DryTech 2006. Issues like waste emissions and energy use were an integral part for the future viability of kiln drying operations. In a first step to better understand their impact, research was presented at DryTech 2006 that quantified the liquid emissions that come from the kiln and what options are currently available for its disposal or possible utilisation. Limited copies of the conference proceedings are still available from FIEA offices. Programme Images
Programme Summary The Timber Preservation 2006 series attracted over 180 delegates across New Zealand and Australia. Speakers from North America, New Zealand and Australia presented a wide range of issues, including; opportunities in a changing market, challenges including shifting to higher cost products, an increasing array of new products and companies supplying the market, a greater variability in the performance of new products and education of the industry, specifiers and end-users. An understanding of issues currently being addressed by North American and European treaters was discussed as being an essential part of future planning by the industry in Australasia. In an industry where process or product innovation has generally been slow, Timber Preservation 2006 was used to announce new developments with pilot and commercial trials in the US of "micronising technologies" that will significantly reduce the size of the component particles used in preservative solutions. The new technology is expected to be introduced into New Zealand and Australia in 12-18 months. At both events, the issue of the timber treatment industry working more closely together to represent the industry and to promote and increase the use of treated timber were discussed. It was agreed that efforts to date have largely been disjointed and because of this fragmentation, not as effective as they should have been. Finishing on a strong positive note, in Australia it was agreed that a number of key industry associations (led by the TPAA) would meet with A3P to discuss options for a single united voice to represent timber treaters on a wide range of Australian issues. Limited copies of the conference proceedings are still available from FIEA offices. Programme Images
This years FIEA Annual Conference attracted a large audience of over 120 representatives from throughout the New Zealand forest and wood products industry. There was significant interest in the new rules for visual and machine stress graded timber in New Zealand and the SP Structural Grades that are now being rolled out in Australia. Delegates were forewarned that these changes are going to have significant implications across the Australasian industry - to forest owners, wood producers, wood manufacturers, specifiers and end users. In New Zealand the DBH citation of the NZS3603 Timber Structures Standard will drive changes to the new lumber grading regime. For suppliers of lumber into both markets, its of some concern that the overhaul of both grades couldn't be aligned more closely. There was also considerable discussion at this event around strategies to move beyond supplying low cost commodities such as structural lumber. A number of case studies from companies like 42 Below, Design Mobel and Stora Enso Australia were outlined demonstrating how innovative strategies, thinking and design will lead to new opportunities beyond those currently being explored. A great example of this thinking can be seen in the New Zealand dairy industry. Compared to the forestry and wood processing sector, dairying appears spectacular in its growth and development. Over the past 30 years the number of cows being milked has increased by 86% with a further increase in per cow production of 38%. The combined effect of this has seen the milk available for processing rise by 156%. Like the forest sector, dairying is in the commodity business. The issue of why does one primary producing sector exporting a commodity product perform well and perhaps another not so well - is it all down to innovative thinking and investment into Research and Development. Limited copies of the conference proceedings are still available from FIEA offices. Programme Image
Programme Summary ScanTech 2006 ran in both Rotorua and Coffs Harbour and attracted a large audience of major softwood producers throughout Australasia. This two-yearly series focused on new and emerging technologies in scanning and optimisation in the saw-mill. A line-up of all major technology providers were drawn in from the US, Canada, Italy, Sweden, Finland, Australia and New Zealand to the series - the most comprehensive line-up ever seen in this part of the world. Improved efficiencies in wood recovery are said to be built on three pillars: scanning the wood to know its shape, size and characteristics, optimisation to determine the best solution and material handling to correctly saw the optimised solution. Key technologies discussed included, new developments in X-ray scanning that combined stem shape with internal log characteristics to open new doors for pruned log processing. Mill wide systems design through Ethernet networking also attracted significant interest through advances for "across the mill" networks. This allowed data connectivity between all aspects of control, production, optimisation, QC, and management and corporate information systems within the mill - to improve efficiencies and recovery. The pace of change in these technologies was, and will continue to be, extremely fast. Scanning and optimisation technologies are in many cases already working in large American and European mills. The only major drawback to this part of the world appears to be the cost of adoption by processing companies and the constraints of engineering and mechanical design to keep pace with ever increasing scanning speeds. Feedback from the event was excellent and many delegates have already been asking when another will be held. The next ScanTech series is scheduled to run before May 2008. Programme Images
Programme Summary SawTech 2005 used a series of practical workshops, "hands-on" exhibitions, demonstrations and focus groups to maximise the interaction of leading local and international sawing expertise brought into Australia and New Zealand in late 2005. Designed specifically for Australasian sawmills, SawTech 2005 was met with great enthusiasm and draw over 100 industry professionals from both sides of the Tasman. Machine alignment was one of the key issues covered over the two days. Because of the impact that misalignment can have on consistent lumber production and sawing accuracy, sawmillers were shown how to set up an effective in-mill alignment programme. About two thirds of sawing problems in North American sawmills – this estimate could also be applied to local sawmills – are caused by misalignment rather than saw preparation. A wide range of inexpensive tools such as machinists levels, an aluminium straight edge, a box level or sine bar to measure levels on press rolls, carriage knees, guide reference plates for horizontal and vertical arbor edgers, the use of a stainless steel tight wire for checking straightness, laser measurement systems to measure deviations from level on a carriage track or bed plate and quick check jigs were all introduced as tools that should be used regularly in the sawmill to diagnose and correct alignment related problems. In addition to sawmill alignment, a wide range of other inexpensive tools to accurately measure sawmill machine cycle times and monitor production capacity utilisation were detailed. All were under $5000. Practical techniques to measure bandsaw strain and log movement, systems for assessing top wheel movement in band saw operations, saw blade temperature, saw blade displacement and glue line pressures were all part of a "Sawmill Toolbox" demonstrated. Some of other and new and developing technologies discussed by sawing specialists included pushing the envelope with feed speeds through super critical speed sawing, the design, maintenance and operation of thin kerf saws and on-line band saw monitoring and control using bandsaw deflection monitoring, depth of cut and size control board deviation scanning. Limited copies of the SawTech 2005 proceedings are still available from FIEA offices. Programme Images
Programme Summary The importance of Asia as a vital market for New Zealand’s wood producers was once again highlighted by a strong turnout of over 100 delegates at our Annual Conference - Wood Markets Asia. General Managers, Directors and Marketing Managers from throughout Australasia attended an event which provided delegates an in-depth look at exporting opportunities and threats. The August 2005 event, which was held in Auckland, saw 20 internationally recognised speakers presented two days of detailed breakdown into the key wood markets of China, Japan, Korea, the Philippines, Thailand, Indonesia, Vietnam and Australia. In addition, projections and issues relating to trade in wood chips, logs, engineered wood products and MDF within the region were also given. Clint Laurent, Executive Director of Asian Demographics, set the scene with an invaluable analysis of changing growth, income and spending patterns within the Asian market. Dr Chris Gatson, Director of Markets & Economics at Canadian based Forintek Canada Corp, gave valuable insights into China’s wood supply and demand issues, including locating opportunities for exporters in high-end and niche products in panels, lumber and components. Stephen Jacobi, CEO of NZ Forest Industries Council, presented important developments in the removal of technical barriers discriminating against the use of Radiata Pine in China. While work was still needed, major breakthroughs been made and have come from three years of hard work by the Council and government organisations. China now sees NZ as a competent partner in the Chinese construction industry and the perception of NZ Radiata Pine as being only suitable for packaging and plywood has been lifted. Overall the annual conference was a great success, with delegates rating this event as one of the best and most informative conferences in recent years. This shows the conference continues to be a fantastic opportunity for the industry to meet, network and exchange ideas in the ever changing forestry and wood products industries. Programme Images
Programme Summary Maintenance, engineering and production staff from wood processing operations throughout New Zealand and Australia attended the latest series of technology events run by FIEA in Rotorua on 4-5 April and again in Melbourne on 7-8 April. The two days of practical seminars, managed exhibitions and focus groups provided an update on new technologies, tools and systems that can be employed jointly by the maintenance and productions teams to improve a mills performance. Dennis Suarez, ex Weyerhaeuser from the US again provided a valuable insight through a series of case studies how a range of wood processing and manufacturing operations had significantly improved their performance by committing to improving in-mill communication. Dennis outlined how more innovative organizations understand the importance of „real communication‰ and are able to effectively cultivate dialogue into a strategic strength. At the mill level, five steps toward building stronger and more effective communication between production and maintenance were discussed: senior management makes it a priority, a visible partnership is created between maintenance and production management, structure is built (teams to support functional areas of the mill) so daily operations can be coordinated, creating balanced operations by clustering related machine centres or supporting processes in the product flow and celebrating team successes. Detailed cases studies were used to demonstrate how mills have effectively linked their maintenance and production teams. At Weyerhaeuser's Cascade Lumber operation for example, the mill after harnessing the cooperative efforts of all mill personnel found recordable incident rates dropping from 14 to 3 in six years, resulting in annualised savings of US$200,000, an increased average production of 32 percent in 7 years, yielding US$6.7 million dollars in annualised gross margin, increased net recovery by 10 percent yielding a reduction of US$3.45 million dollars in annual log costs and became recognised within the company and industry as the benchmark in lumber quality. Other key themes included setting up on-site maintenance system audits, how external service providers can add value to a mills operation, life cycle comparisons of chains and wear surfaces, power factor correction and how the correct power factor in the mill can improve profitability through lower maintenance costs, improved system capability or reduced line charges from the power provider, on-site energy audits, options and advantages of variable speed drives, automating lubrication systems and technologies that have been developed for computer based maintenance planning. Programme Images
Programme Summary Wood Manufacturing 2005 was a series of practical workshops and managed exhibitions that ran for New Zealand and Australian wood manufacturers in March 2005. Close to 200 persons attended the two technology programmes. In addition to key Australasian expertise, a number of North American, UK and European wood manufacturing specialists travelled specifically into Australasia to participate in this series. FIEA Director Brent Apthorp says, "This Australasian programme was titled: The Profitable Wood Manufacturing Plant Tooling, Technology and Design. The series provided a unique opportunity for wood manufacturers to learn first hand about a wide range of new product and process technologies that can be adopted to improve their operating performance." Fingerjointing, timber gluing and laminating is the most widely recognised and popular of the FIEA technology updates. In addition to new technologies, the practical workshops provided fingerjointing operators „hands-on‰ sessions and detailed information that can be used on-site for improving machine layout (both for horizontal and vertical jointing), operations and productivity. One of the best independent fingerjointing consultants from North America led the practical fingerjointing sessions. Since first brought out by FIEA to work with local companies, Norbert Milota has been used by leading Australasian wood manufacturers commissioning, troubleshooting and providing training on a wide range of machine types. Wood Manufacturing 2005 covered optimising plant layout and design, automation of stacking, cross cutting sorting and grading operations, scanning applications best suited to pine, cutting patterns to maximise clear lumber recovery, fingerjointing technology update and practical operational guidelines, developments in new gluing formulations, glue clamping systems and options for glue bond drying, monitoring wood manufacturing performance and material handling equipment to improve product and process flow in the plant. In gluing, as well as updates on developments with structural and non-structural adhesives, details on the revolutionary one component polyurethane adhesives were outlined with case studies on European and New Zealand wood manufacturing facilities that have recently switched from using multiple adhesives to the new one component PUR adhesive. Case studies of wood manufacturing operations using RF curing and pressing, details on new acoustic technologies to segregate fingerjoint blocks before jointing, results on research on defecting and impacts on glulam stiffness and systems for real time monitoring in the dry-mill were also covered in the series. Programme Image
Programme Summary This series of practical workshops and managed exhibitions proved to one of the most successful technology events run by FIEA. With so many recent changes to the timber treatment industry along with a raft of other major developments that will directly impact on the future operation and viability of these companies, some 250 persons directly involved in timber treatment in New Zealand and Australia attended this practical series. In Australia, the APVMA is working to a tight timetable. It is working with timber preservative suppliers and the treatment industry to develop a system of labeling for CCA products and treated timber. It is expected that the APVMA will release the final outcome of the review by February 2005. This ban follows hot on the heels of changes to the use of CCA treated timber in North America and in Europe. In North America, the voluntary decision made by the industry to remove CCA treated timber for use in residential applications has gone relatively smoothly since the changeover on 31 December 2003. Timber treaters and retailers have largely replaced CCA with new alternative treatments such as ACQ and copper azole. The use of CCA treated timber in the UK from 30 June this year is also banned in residential and domestic constructions as well as applications where this is a risk of "repeated skin contact". It is reported that like North America, a high percentage of timber treaters in the UK have already switched from CCA. For Australia, the APVMA review calls for restrictions on CCA treated timber being used in situations like decking, playground equipment, handrails and picnic tables. Changes to treatment plants, the treatment industry and distributors of CCA treated products, on both sides of the Tasman are going to be significant. Details of major changes to timber treatment standards, new formulations and how the industry in North America and Europe has planned and developed new strategies to grow their businesses was addressed by Mary-Anne Dalkowski, Marketing VP, Osmose Canada and in presentations by key presenters from throughout Australasia. In New Zealand and Australia, a suite of standards covering the treatment of solid wood, reconstituted wood products, plywood, LVL and glulam has, with the exception of glulam, being finalized. These new standards are likely to be published shortly. Details of these changes and implications on the local industry were also covered in the workshops. Along with these changes, competition to treated timber wood products continues to grow at an alarming pace. Already, over two-thirds of North American extruded wood plastic composites (WPC’s) are currently being used in outdoor residential decking and railing systems. The WPC share of the estimated US$3.5 billion residential and industrial decking and railing market in the US has grown considerably from about 2 percent of the market in 1997, to 8 percent in 2000 to an estimated 20 percent by 2005. Penetration of WPC’s into the decking market has attracted significant attention by both forest products companies and plastic extruders alike. Recent success in WPC decking products has been the result of establishing strong marketing and communications strategies and developing highly competitive distribution channels. The largest supplier of WPC decking products in North America for example is currently spending about 10 percent of the company’s sales on marketing and communications. They have developed in a very short space of time a manufacturers reputation among distributors for providing quality products, services, financial returns, support and incentive programmes along with quick response systems. Mary-Anne Dalkowski outlined how the wood products industry in North America is countering moves by WPC’s and changes to CCA treated timber through the development of strategies for full supply chain promotion. The industry in Australasia if it is to survive will be required to develop similar strategies – collectively and quickly. All those who are trying to keep pace with the myriad of new timber treatment standards and regulations, which are being imposed on their operations and those who are planning for their ongoing survival were rightly involved in this practical independent series. Some serious open discussion on both sides of the Tasman on how the industry should be more effectively coordinated and organised was also held. It is hoped that as a consequence of timber treaters raising their concerns, that real progress on more effective representation and communication for the industry will result.
Programme Summary The FIEA Annual conference in New Zealand drew in all major forest owners, wood processors and manufacturers from throughout New Zealand in addition to key pine producers and distributors from Australia, Canada, the US, Chile, South Africa and Europe. Over 170 persons attended the 29-30 June event in Nelson. In New Zealand one could understand the interest with over one million hectares or 67 percent of the pine estate receiving some form of pruning. The future of the industry is tied irretrievably to the future of clear pine. Increased production from other clear pine producers and substitutes will mean increased competition with prices expecting to trend lower, particularly over the next five years. "The message from leading commentators was clear," says Brent Apthorp from FIEA. "Clear pine lumber is currently a commodity. Stay in commodities, but only if you are a low-cost supplier. If unable to compete with competitors outside Australasia, the industry needs to move, and move quickly, into higher value wood products." The conference provided the most up to date analysis of current and projected volumes and quality of pruned pine available from New Zealand, Australia, the US South, Chile, Brazil and South Africa in addition detailing the significant changes that have occurred to the end uses and demand for clearwood in the US and Asia. New harvesting, log scanning and timber drying technologies that have recently been developed to maximise clear grade recoveries were discussed. Two case studies at the end of the conference provided some insight into how to make a shift from exporting only clear lumber to offshore manufacturers. Tenon Ltd, formerly Fletcher Challenge Forests, outlined how they have moved successfully beyond just understanding the resource and producing high quality clear boards for their customers. They have partnered other companies in the supply chain to provide the necessary expertise and access to new markets and have together developed innovative strategies for processing, marketing and distributing clear pine. The other case study outlined how design and branding expertise and a secure supply chain being offered by a European company have now provided unique entry to a mature market for clear pine from New Zealand.
Programme Summary The opportunities for improved sawing conversion, grade recovery, production and quality were highlighted in four regional workshops run for new Zealand and Australian sawmillers. Terry Brown, internationally recognised for his development of systems and tools for lumber size control, demonstrated the benefits of improved lumber quality and grade yield, reducing target sizes to increase recovery and fewer unscheduled saw changes in the mill for sawmills setting up QC programmes. For mills sawing 100,000 m3 lumber each year, gains of $20,000 to $1 million were shown to be readily achievable. Detailed studies in US and Canadian mills have demonstrated a 0.25mm reduction in target size will equate to a 0.6 percent increase in yield. With a headrig cutting 30 percent of lumber from all saw lines in a mill, the potential for a 0.25mm reduction in sawing aim size is $63,000 per annum. Mills setting up a size control programme have also shown that a target aim size reduction of 0.8mm or more can be achieved. The theory behind measuring sawing variation, the principles for effective implementation of size control programmes and benefits were highlighted with two recent case studies. Installing four scan zones in Weyerhaeuser’s New Westminster operation in Canada and measuring sawing variation in cants and sideboards produced from the canter quad and lumber sawn in the edger and gang saw resulted in improved recoveries of three percent in just one year for the mill. Much closer to home, a case study on Carter Holt Harvey’s Myrtleford operation in Australia was detailed. In 2002, a mill wide process improvement study identified the quad bandsaw as being a major source of downgrade. The mill introduced real-time monitoring of the board thickness. As the centre cant contains approximately 60% of the volume of lumber being processed in the mill, measurement at the multi-saw had the potential to add the greatest value to the mill. The capital expenditure for the project was justified on the basis of reducing stoppage time for manual measurements of lumber size and reducing planer hit-and-miss. The benefits after installation were immediate and substantial. In addition to Terry Brown, the principal suppliers of new technologies using scanning or high-resolution video sequencing systems to monitor sawing accuracies on all sawing centres on a continuous basis (real-time size control) were presented to Australasian sawmills. Manual systems, although clearly demonstrating considerable value to the mill, are being replaced by real-time data collected from optimizer lasers. Each machine centre in the mill can be monitored continuously with measurements taken from every sawn face on logs, cants, flitches and boards passing through the mill. Larger Australian softwood mills have recently installed two of these new systems in Myrtleford and at two mills in Mt Gambier. The four principal suppliers of the new commercial systems, SeeCon, SiCam, SizeCheck and the Surveyor STM 800 demonstrated the benefits of both continuous single and multiple measurements of boards. Some of the new systems can take up to 100 measurements per second with an accuracy of 0.1 to 0.15mm. Information on setting up size control programmes and the new real-time systems was outlined in the workshop proceedings. Programme feedback Feedback to the workshop series by larger softwood operations in both New Zealand and Australia was some of the best received for any technology programme run over the past six years. Programme Images
Programme Summary The cost of on-site energy is going to increase significantly, and sooner rather than later. That was one message repeated during both Energy Management is Smart Business two-day events. The over-arching message was that, on-site energy use can be successfully managed, and significant bottom-line savings can, and are being achieved. Further more, often significant savings can be had by making low-cost improvements that have a very short pay-back period. In many cases valuable savings can be made with a little forward planning and staff education. The first day of each programme was opened by Heather Staley, CEO of the Energy Efficiency and Conservation Authority (EECA), outlining the governments approach to New Zealand’s current and future energy requirements, including a focus on achieving a 22% increase in the production of energy from renewable sources. The wood industry is considered to be one of the sectors with the greatest potential to provide renewable energy, possibly becoming self sufficient with regard to its energy requirements. The remainder of the morning session largely focused on establishing a firm understanding of the electricity industry in New Zealand, its structure and the issues that arise from the current generation and supply environment. Brian Cox (East Harbour Management Services) looked at current and likely future issues facing the industry. He also gave an overview of other generation options, including renewable energy developments, where they are at now, and what their expected potential is. A short presentation from EECA outlined some areas of support that they offer, as a government agency, to encourage energy use efficiency. The afternoon session outlined a range of practical tools that can be used by individual sites, to better understand, monitor and improve their energy use efficiency (Hitesh Patel, Energy Pro - Erin Roughton, EMSOL - Jonathon Kay, Energy Intellect - Geoff Bennett, Energy & Technical Services, and Garry Mahoney, Honeywell). Also, Raymond Bol from SKF outlined some specific steps that can be taken to improve individual machine’s performance through equipment drive improvements. Day two of the programme opened with Grant Smith of Meridian Energy, giving attendees the "uncut" version of the energy industry, from the retailer’s perspective. This was particularly enlightening for many, and was followed by Richard Green (Business Engagement) discussing how energy users might be best able to negotiate supply contracts to their best advantage, both as individual site customers and as multiple site groups. This was followed by John Penny of Vectek Electronics, outlining how to manage inconsistencies in energy supply, such as "voltage sag" and "power factor" fluctuation to equipment. Peter Robinson (MWH) looked at an initial site/project assessment for a cogeneration plant, pointing out that very short payback hurdles for such projects, are generally not soundly based, but are often the reason given as to why a project will not proceed. Meridian Solutions later outlined their approach to onsite energy production and supply, where they will consider, on a case-by-case basis, developing, owning and operating onsite energy plant from which the onsite company can purchase the resulting energy. This generally involves the use of onsite waste streams for energy production. Fuel, especially where co-combustion is being considered, must be carefully assessed, was the message from Tony Clemens of CRL Energy. Tony outlined some of the variations in burning efficiency and emissions, which might be expected from two variations of fuel mix. This was followed by an interesting co-generation case study, presented by Allan Estcourt (Allan Estcourt Ltd). This case study looked at a particular site, the parameters of the co-generation project and the options considered. The final conference presentation was made by EECA, and outlined the "Emprove" initiative that has been developed by government, to encourage efficient energy use and renewable energy projects. A combined conference and local FIEA branch dinner was held on the evening of the first day at each venue. Guest speaker was Simon Adamson, Trade & Enterprise NZs Senior Trade Commissioner for South America. Simon gave a very enlightening presentation that outlined where the South American wood industry was, where it has developed to and where he believes it is going. Simon's portrayal of the South American industry, and information such as their exporting of pine plywood to NZ and Australia in recent months, was sobering information for many. Programme feedback Feedback from programme participants included:
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Programme Summary Over 150 sawmillers were involved in the recent series of technology workshops and managed exhibitions in Noosa Heads, Australia and Rotorua, New Zealand. Sawmill managers, engineers, production staff and sawdoctors from throughout Australasia met to discuss the latest developments in saw design and maintenance along with new scanning and mill optimisation technologies that can be adopted by mills to improve their sawing performance. The first day of each programme detailed how improved cutting accuracies in North American and New Zealand mills have been achieved by using stainless steel saws instead of conventional alloy steel. Guided saw performance and the importance of measuring sawing accuracy were also discussed. Those involved in monitoring lumber sizes were told that guided saw operations do not conform to normal board size variation models currently been used in sawmills. Although there is random variation present along both edges of a board, observations of boards cut by guided saws in a single arbor gang edger reveal a dominant pattern of sawing inaccuracy, consistent and accurate board thickness at the closest edge to the guide, and a wedging effect, caused by the saw’s tendency to bend to one side or the other, toward the board’s edge. CHH fibre-gen demonstrated the benefits of real-time on-line measurement of multiple sawn lumber widths, which can be taken with the newly developed Surveyor STM800. The size control system has been installed and trialled in several mills in New Zealand, Australia and North America over the past 15 months. Simple tools and equipment to set up and measure alignment on the carriage-head rig, band mill, and chipper canter were outlined by Alignment Engineering with a number of case studies from Australasian mills demonstrating the financial benefits from setting up an in-mill machine centre alignment programme. Detailed information on the case studies and procedures that should be followed in the mill were included in the workshop proceedings. The second day focused on log and board scanning systems. MPM Engineering detailed why log sorting by cutting pattern rather than diameter class is preferable. Mill studies have indicated gains of up to seven percent in sawn recoveries can be achieved using log-sorting systems to fit patterns (products) or geometric shapes into the log instead of sorting by diameter class, which is more often than not used by mills for log optimisation. A number of leading sawmill equipment and scanning suppliers outlined the latest developments relating to 3-D scanning and optimisation; the significant grade value improvements possible through optimised grade sawing and advancements in high-speed band-sawing where feed speeds of 150m/min and saw speeds of 100m/second are now being used in sawmills. Technology developments used in curve sawing with saw arbor and guide design increasing the saw service life and new designs in chipping head configurations that reducing knot tear out in logs were also discussed. Some of the more exciting developments detailed at the Portland woodworking show earlier in the year and discussed at SawTech 2003, relate to web-based technologies which are now being used successfully for machine and mill optimisation and information management in sawmills. Most sawmills can improve their sawing efficiencies by a minimum of 10 percent by introducing a process management system. The new "Mill Wide Web" or sawmill process management system outlined by presenters provides a centralized data collection, monitoring, reporting and data archiving system and collects real time data from optimizers, PLC systems and other quality control systems in the mill. Real time monitoring of mill wide QC and lumber sizes and piece volumes, recovery and log distributions as well as statistics and information on machine utilisation and can also be secured through the new system. Programme Feedback Feedback from the programme participants included:
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Programme Summary Our approach towards the Annual Conference, for the past few years, has been to choose a topic that we believe, and experience in other countries suggests, is likely to impact on the forest products and associated industries, in the near future. Green Building was another of these topics, and it generated considerable interest from individuals and companies representing a broad cross-section of industries and professions. There were a number of diverse topics covered, from defining and measuring "how green is green", when referring to construction materials and overall energy performance, to modern technology that can assist with the design of structures in a manner that minimized the effects on others and maximizes value from a site. Brenda and Robert Vale gave an opening presentation that highlighted that "green Building" or "Sustainable Development" is not just a case of using environmentally friendly building materials, such as wood, but also includes the need to be aware of, among a great deal of other things, the energy used in the operation of the building throughout its life. For example, careful design can have a huge effect on the ongoing heating costs. Linda McPhee outlined the impact that "green" or "sustainable development" awareness is having on the North American markets, and the challenges and opportunities for the forest industry that are coming from it. Wood waste recovery and use is being targeted as a key area for development. Information management and new technologies are proving key to furthering overall development. Ian Taylor’s presentation was very visual and high energy. Ian outlined how technology that he uses has progressed in recent times, outlining the speed that it has, and still is, evolving. Ian outlined the database of land and services information that his company "Terralink" now has available to it, and the three dimensional (3D) programming that can use the information to provide a huge variety of visual projections. These include such services as how a road can best be developed through a section of forest, or what the view from a second storey window, of a yet to be constructed building will be. Nils Larsson also outlined a number of tools that can be used by design professionals to assist in evaluating the environmental performance and the impact of larger scale developments, both the construction phase impacts and the long term operational impacts. He hopes to have many of these tools available via the internet, in the near future. In addition to these more technical aspects of the conference, there were also a number of very visual presentations, highlighting the use of timber and a variety of sustainably developed projects. Owen Griffiths of McIntosh Timber Laminates, Hugh Tennent of Hugh Tennent Architects, Alan & Sharon Drayton of Natural House Builders, and Brenda & Robert Vale, all had exceptional examples of properties that had been sustainably developed to some level, depending on the clients wishes. There were some stunning projects, both visually and in energy performance. Programme Feedback Feedback from the programme participants included:
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Programme Summary Both technology programmes were very successful with over 150 participants from the Australasian forest products industry attending the two events. For the first time, part of the conference in Melbourne was split into two separate streams, one focusing on softwood drying technology and the second on hardwood drying technology. This gave the opportunity for all attendees to hear the more generic presentations and then separate for the more focused softwood and hardwood information. These focused streams were well received. There were several new drying technologies outlined, with each generating significant interest and their own unique questions. Two new entrants to the Australian market include the DePump technology, and contoured conventional kilns. The DePump dehumidifier units have been particularly popular in New Zealand with companies looking at lower capital costs, the ability to eliminate boilers from the drying operation, and a drying system that can produce high quality appearance grade timbers with minimum discolouration and checking. Over 100 units have been installed in New Zealand in the last four years. The contoured kilns produced by John Fogarty also generated a lot of interest where the roofs of the kilns are rounded rather than flat-topped. The company, and the University of Canterbury that has been doing research on the new shaped kilns, both claim that energy savings and more uniform airflows within the timber stack have been achieved with this new design. New Zealand companies have installed over 20 of these new kilns over the past four years. Progress on vacuum drying with hardwood species and microwave drying in Australia were also outlined. One of the more recent initiatives providing significant dividends to kiln drying operations is sorting lumber prior to drying. New technologies offer excellent opportunities for drying schedule optimisation and additional gains in grade recovery. Two new innovative technologies for moisture and density measurement developed by local researchers in conjunction with major softwood producers were detailed in the workshop series. Fletcher Challenge Forests (FCF) and the Institute of Geological and Nuclear Sciences developed the first green density lumber sorter in 1999. The system uses low energy gamma rays placed upstream of lumber sorters in the green mill. It enables sorting of slow, medium and fast drying batches and lumber unsuitable for further kiln drying and msg/msr processing. From commercial drying operations, low moisture batches have been found to take up over 50% of production. Using segregation, low moisture batches can have drying times reduced by 40% or more. The system, the Surveyor LDS 200, has been upgraded and is being marketed by CHH Fibre-gen. Surveyor systems measuring over 120 lugs per minute, since the Kawerau installation, have been set up in three Carter Holt Harvey and two Weyerhaeuser Australia mills. Another two installations are planned in the next few months. Based on existing operations, a mill producing 100,000 m3 per annum is estimated to gain NZ$320,000 by using the density sorter. The second in-line system is being developed for the dry-mill. Like the green density lumber sorter it is being developed by a local microwave engineering company, Keam Holdem Associates, working alongside FCF and Weyerhaeuser Australia. Recent trials show that moisture and density can be derived to an accuracy of ±1% and ±10kg/ m3 respectively. Commercial trials of the new microwave system are expected in the next few weeks with commercialisation expected before the end of this year. Programme Feedback Feedback from the programme participants included:
Programme Summary Both technology programmes were very successful with 150 participants from the Australasian forest products industry attending the two events. A further 70 forest harvesting contractors attended the Forest Industries Contractors Association "MainTech in the Forest" event that was held in conjunction with MainTech 2003 in Rotorua. There were also a large number of companies represented, which supply the forest products industry. There were a number of key issues addressed, which impact on mill performance. Dennis Suarez, Maintenance Manager at one of the most efficient of Weyerhaeuser’s mills, gave several presentations covering the Weyerhaeuser experience of linking manufacturing and maintenance excellence, employing tools and technologies in a systematic approach to preventing and detecting maintenance issues, as well as presenting a toolkit to assist with the planning and installation of new equipment. Don Johnston and David Langman gave two very popular presentations on the first day, at both venues. David and Don took an open minded look into the changing needs of the forest products industry, and developing the business case that supports a change in thinking for many, as to how operational and maintenance staff are managed. They also challenged how capital expenditure to support maintenance is viewed by many. Neil Arthur from SKF Reliability Systems also presented valuable insights into implementing strategies for sustainable mill performance and the use of computerised maintenance management systems, supported by recent practical case studies. All presentations at the conference were recognised by participants, as being of a very high standard. Programme Feedback Feedback from the programme participants included:
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