By Jennifer McCary
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At the primary headrig, logs are scanned for opening face and linear positioner setworks position the three-knee, 17-degree tilted carriage. Pre-set parameters allow for removal of a "shim", which includes the slab, first board, and saw kerf allowance. Shims are sent to a 5-ft. horizontal Salem resaw, where the slab is removed and then to a Salem board edger with Inovec optimization.
Overview of Inovec edger optimizer preceding board edger.
"We feel for us a tilted headsaw simplifies log turning," states Andrews. "You can see the grain better and you have more control of the log." Saw kerf at the headrig is .137 in.
The 6-ft. band headrig makes four passes and sends four-sided cants to a circular merry-go-round feeding a 6-ft. linebar resaw. A pre-positioning operator turns the cant for best grade. In general, the resaw operator will process the cant to remove all No. 2 lumber.
There are four dispatch options from the resaw. Boards may go directly to the optimized drop saw trimmer or to the optimized edger. Multiples can go to the horizontal resaw or to a combination gang and edger. Boards from the horizontal resaw drop to an unscrambler and proceed to the optimized edger. Small low-grade cants go to the gang, which processes 4x4s and can also remove a front board on the edger side.
Kerf at the linebar is .140 in. and .135 in. at the horizontal resaw. The gang also runs a .140 in. kerf with 112 blades. Kerf size is less critical at the edger, since the kerf can be put through the wane of the board. The edger uses a stiffer plate and saws a .245 in. kerf.
At the green chain, lumber is graded and sorted for both grade and color. More than 30 different sorts are made. Low-grade lumber and pallet cants are sold green. No. 2 and Better are kiln dried.
Roughly 80 percent of total production is kiln dried. Red oak goes to a 500 MBF capacity Irvington-Moore pre-dryer. White wood species go into one of five computer-controlled kilns-three Irvington-Moores and two American Wood Dryer units. Total drying capacity is 250MBF. A wood-fired 165 HO low-pressure Hurst boiler supplies heat.
Forklifts include Hyster 280, 200, and 180 models and a Taylor THD 250.
Since 1990, managers have experimented with various types of stickers to maximize airflow in the kilns. They've settled on Breeze-Dried(tm) sticks, which have cross-directional flutes. Like traditional fluted stickers, Breeze-Dried sticks only touch the lumber at the high points. But instead of air and moisture having to travel six feet to exit the package, they only have to travel two and a half to five inches. This has significantly reduced sticker discoloration problems.
All kiln-dried lumber goes to a grading station where an Integrated Solutions system scans its width and length. The computer compares it to pre-programmed parameters for grade and species to ensure that it meets these criteria and automatically sends it to the correct bin.
By way of an overhead crane, all high-grade packages are export banded with 3x4 blocks on the bottom. This practice benefits both export and domestic customers because it saves time for lift operators and improves customers' shipping and receiving efficiency.
Approximately 40 percent of production is exported to Canada or offshore through the Port of New York. The remainder goes to domestic markets.
For the moment, the emphasis is on fine-tuning the new mill and production capabilities. Down the road as production increases, Ryan expects Deer Park's next project will focus on a larger boiler and increased kiln capacity.
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