NEW
RAUTEPRO
XY CHARGER
VENEER TAPING
INCREASES
YIELD
SAN GIORGIO IS
DEVOTED TO QUALITY
IMPROVEMENT
Issue 13
Raute Customer Magazine
Published by Raute Corporation
Russia’s
Greenfield project
was built up from zero
to full production
in eighteen months.
PLYVISIONS
1
RAUTE NOW RAUTE NOW RAUTE NOW RAUTE NOW RAUTE NOW RAUTE NOW RAUTE NOW
Happy New Year 2011
FOR RAUTE, 2010 was a year of recovery following the catastrophic 2009,
even though it was still not acceptable
in terms of financial performance. Worth
of special mention in regards to Raute’s
order intake in 2010 was the strength of
the Asia Pacific market and the importance of the demand for LVL technology.
2010 was a time for Raute to revisit
and modify our strategy so that we could
better align ourselves with the postrecession situation. We have reaffirmed
our commitment to add value to the production processes of the veneer, plywood
and LVL industries by providing solutions that facilitate profitable and environmentally sustainable production. We
will continue to be the global leaders in
the development of production technology for the industries we serve.
Raute’s revised strategy can best be
summarized in our new vision statement
– “Profitable Solutions to All Customer
Needs”. Please take a minute to reflect
on this statement as there is important
meaning in every word. In order for
Raute to realize this vision as we move
forward, we must become even more
customer focused than we have been in
the past. We will need to provide even
more attractive technology services to
the customers looking to modernize and
optimize their existing capacity. In addition, a new aspect of our strategy is a
greater focus on serving the emerging
markets demanding lower cost solutions
and simpler technology. Cost efficiency
and quality in all of our operations will
remain an absolute must. The high level
of competence within our own people
continues to be an essential element in
securing the benefits of this new strategic focus. Consequently, we will continue to invest in our people to ensure
they possess the right skills, tools and
attitudes.
Raute was pleased to receive an
order for an LVL mill in China near
the end of 2010. It is the most concrete
and recent indication that producers
in China are shifting towards the use
of more advanced technology also in
veneer-based wood products industries.
It also clearly indicates that the Chinese
producers are prepared to respond to
the more stringent end-product quality
requirements of the international markets they intend to serve.
Once again our team has collected
a number of very interesting stories
for this issue of PlyVisions. This issue
reflects the current market situation
and some of our new strategic focus
areas. On the one hand we have a strong
focus on our customers in Russia and
their technology. On the other, we talk
about modenizations, upgrades and services as well as what our customers have
achieved by investing in them. Interesting reading for sure!
On behalf of Raute, I would like to
thank our customers and other business
partners for their support during 2010.
We are looking forward to working
jointly with you throughout 2011.
Once again, Happy New Year! May
you all have a fulfilling and prosperous
2011!
Tapani Kiiski
President and CEO
WE WILL CONTINUE TO BE THE GLOBAL
LEADERS IN THE DEVELOPMENT OF
PRODUCTION TECHNOLOGY FOR THE
INDUSTRIES WE SERVE.
2
PLYVISIONS
CONTENTS
12
Raute now
2
New RautePro XY charger 4
New services: knives, knife grinders
and knife management 6
Veneer taping increases yield
and improves quality 8
Continuous development guarantees
competitiveness 10
RAUTE IN RUSSIA
Insight into the Russian plywood industry 12
New Greenfield project 17
Vyatskiy Fanernyi Kombinat invests in new mill 20
Lesdrevmash 2010 21
San Giorgio is up to the challenge 22
10
Cover photo: Veli-Matti Lepistö
6
PlyVisions is Raute Corporation’s Customer Magazine.
Editor-In-Chief: Veli-Matti Lepistö
Editor group: Eija Salminen, Matti Ukkonen, Olga Harju
Layout: Onnion Oy Printing house: Libris 2/2011
Address changes: [email protected]
Publisher: Raute Corporation, P.O. Box 69, FI-15551 Nastola,
Finland, tel. +358 3 829 11, fax +358 3 829 3511
Copyright Raute Corporation. All rights reserved. Reproduction
permitted only with permission from Raute Corporation.
www.raute.com
WELCOME TO LIGNA 2011
30 May–3 June in Hannover
Ligna Hannover is an international hub
for the woodworking and wood processing
industries and is integral to the transfer of
knowledge and networking.
You are warmly welcome to visit
our stand J38 in Hall 27.
ISSN 1459-3165
PLYVISIONS
3
NEW TECHNOLOGIES AND SERVICES NEW TECHNOLOGIES AND SERVICES NEW TECHNOLOGIES AND
New, RautePro XY charger
– PRECISE ACCURACY
AT AN AFFORDABLE PRICE
RAUTE’S NEW XY CHARGER ENABLES YOU TO GET THE MOST OUT
OF YOUR VALUABLE RAW MATERIAL. IT IS AN AFFORDABLE WAY TO
REPLACE YOUR AGEING MECHANICAL CHARGER AND WILL ENSURE
YOU ACHIEVE HIGHER CAPACITY FROM YOUR PEELING LINE. ONLY
MINOR MODIFICATIONS ARE NEEDED TO THE EXISTING FOUNDATION
AND INSTALLATION CAN USUALLY BE ACCOM­PLISHED WITHIN ONE
WEEK!
THIS TOTALLY NEW TYPE of XY charger is intended to replace old mechanical chargers in existing peeling lines. It
has been specially designed as part of a
modernization package for Raute 2HV,
3VM, 3VKKT and 4VM peeling lines,
which are equipped with mechanical
PK chargers. This new stand-alone XY
charger can also be installed ahead of
similar types of lathes supplied by other
manufacturers, subject to inspection on
a case-by-case basis.
UNIQUE CONCEPT
RautePro XY charger is offered as a
direct replacement for old mechanical
charger models. Because it is a standalone system, it is also an ideal modernization solution, since installation time
is relatively short. In most cases, the system can be ope­rational within one week
of delivery.
The XY char­ger’s compact design
and relatively low weight mean that
only mi­nor changes are needed to
existing foundations and the old block
infeed equipment can be fully utilized.
4
PLYVISIONS
SERVICES NEW TECHNOLOGIES AND SERVICES NEW TECHNOLOGIES AND SERVICES NEW TECHNOLOGIES
No mechanical connection to the lathe
is necessary. The system’s robust construction ensures simple and reliable
operation. Instead of using hydraulics,
the XY charger is equipped with modern
AC-servo technology, which results in
significant savings in maintenance costs
and energy consumption.
SIGNIFI­CANT IMPROVEMENT
IN RECOVERY
RautePro XY char­ger has been shown
to improve recovery at the peeling line
through a 10–15% improvement in the
volume of full green sheets recovered
from the face part of the block. The
volume of randoms is reduced by up to
50%, which ensures a quick payback on
your investment.
Peeling line capacity is also im­proved since having the exact block
shape data reduces the amount of nonproductive time between block cycles.
Line capacity can be improved based on
the charger design capacity of 4 blocks/
minute. Further automation of the
peeling process is also possible.
LASERS ENSURE ACCURACY
From three to five fixed lasers are used
to scan the surface of each peeler block.
These lasers provide hundreds of measuring points for calculating the optimal
position of the block in the lathe. Block
positioning correction is performed in
the rotation spindles located ahead of
the lathe spindles. Charger accuracy is
assured by the use of highly accurate
RautePro XY charger
in a nutshell
• true XY centering with rotational correction
• manufactured from standard components
• stand-alone system, installed independently of the lathe
• only minor modifications to existing foundation needed
• short installation and testing period on site
Technical data:
• 4/3 ft or 5/4 ft blocks
• diameter range 100–450 mm (space for 600 mm swing)
• installed power approx. 15 kw
• laser scanners with 0.2 mm resolution
• fully electrical controls
LMI laser sensors and the 25 years of
experience Raute has devoted to developing a block centering algorithm, the
accuracy of which has been proven time
and again.
Following are typical results from
actual cases where mechanical PK20,
PK800, PK500 or PK600 block centering systems, supplied by Raute, have
been replaced with a XY charger (block
diameter 230 mm, core 70 mm):
• full sheet recovery from 49% to 64%
• reduction in randoms, < 4 ft wide from 6.7% to 3.7%.
AN ENVIRONMENTALLYCONSCIOUS DESIGN
RautePro XY charger has been designed
to operate in close proximity to the peeling line operator. With this in mind our
engineers have ensured that the working environment around the XY charger
is quiet and clean. There are no noisy
hydraulic power units and, therefore, no
risk of hydraulic oil leaks. Energy consumption of the low-noise AC-servos is
significantly less than in conventional
log chargers. •
Text: Mikko Vesterinen, Jussi Puranen
Pictures: Veli-Matti Lepistö, Jarmo Ikonen
PLYVISIONS
5
NEW TECHNOLOGIES AND SERVICES NEW TECHNOLOGIES AND SERVICES NEW TECHNOLOGIES AND
RAUTE’S SERVICES
NOW INCLUDE
the supply of knives, knife grinders
and knife management programs
RAUTE IS COMMITTED TO PROVIDING CUSTOMERS WITH EFFICIENT
AND LASTING TECHNOLOGY THAT ADDS VALUE TO PRODUCTION.
THIS COMMITMENT IS SUPPORTED BY CUSTOMER-ORIENTED DESIGN,
THE USE OF BEST AVAILABLE RAW MATERIALS AND COMPONENTS
AND TOP-NOTCH MANUFACTURING PROCESSES. A COMPREHENSIVE
SELECTION OF SPARE PARTS AND VIABLE SERVICES ENSURE THE
RELIABLE OPERATION OF RAUTE MACHINERY THROUGHOUT ITS
LIFE-CYCLE.
nia met these criteria and a cooperation
agreement between Raute and Ravne
was signed at the Ligna Show in Hannover, Germany in May 2009. Under the
terms of the agreement Ravne will manufacture knives bearing Raute’s logo. In
turn, Raute will sell these branded knives
to its customers through its global sales
network.
GOOD KNIVES ARE ESSENTIAL to
KNIFE GRINDING
SOLUTION INCLUDED
quality veneer production. Knives
are used at many stages of the veneer
manufacturing process and are also key
components in much of the machinery
Raute manufactures. As such, the use
of high-quality, well-maintained knives
is of paramount importance when it
comes to veneer quality, raw material
recovery and productivity. In the past,
Raute has delivered machines equipped
with knives from various suppliers. Customers too, have purchased replacement
6
PLYVISIONS
knives that match the performance criteria of various suppliers. Now Raute
has expanded its scope of services
through the addition of knives and knife
management programs.
KNIFE COOPERATION STARTED
IN MAY 2009
Raute carefully evaluated various knife
manufacturers in order to find a supplier whose products meet all the criteria set by Raute and its customers. It was
determined that Ravne Knives of Slove-
Regular and precise grinding is necessary for knives to remain in proper working condition. Some of Raute’s customers take care of knife grinding in-house,
whereas others prefer to outsource their
knife grinding needs. Others still may
want their knife supplier to take care of
both knife grinding and stocking. Raute
wanted to expand and improve its services in this area and so signed a cooperation agreement with Gustav Göckel
SERVICES NEW TECHNOLOGIES AND SERVICES NEW TECHNOLOGIES AND SERVICES NEW TECHNOLOGIES
Peeling line
- peeling knives
- nose bars
- trash gate knives
- clipper knives
Scarf-jointing line
- clipper knives
Composer knives
- clipping knives
Overlaying line
- clipper knives
Maschinenfabrik GmbH of Germany in
2009. According to the agreement Göckel
will undertake the manufacture of knife
grinders for Raute and Raute will sell
them to customers globally.
Raute’s knife management services
also include training packages that
cover correct knife setting, handling and
grinding.
Raute’s knife management program
can also be included as part of a service
Drum & spiral
chippers
- chipper knives
- counter knives
contract so customers can benefit from
the regular monitoring of the condition
of cutting tools and equipment. •
Text: Timo Tikka
COMPREHENSIVE KNIFE SERVICES
Raute is now able to provide valueadded knives and knife management
services to its customers based on extensive know-how in both veneer production technology and customers’ production processes.
Customers can purchase knives
guaranteed by Raute through Raute’s
global sales network and even through
Raute’s website, which is the easiest and
fastest way to place an order.
Raute also offers a comprehensive
knife management program whereby
Raute ships knives directly from its
spare parts center when required. This
service leaves the customer free to focus
on his core business without the trouble
and cost of maintaining an extra stock
of knives in-house.
Raute and Ravne – a partnership in success
Raute and Ravne are two companies fully dedicated to the global market. Our competitive power is demonstrated through innovation, knowhow and the quality of the
products we deliver.
By working together and delivering top-quality knives and equipment to a global
market, Raute and Ravne will continue to strengthen their positions and ensure their
evolution as even stronger and more powerful innovators.
“The cooperation between Raute and Ravne and the synergy of knowledge on
both sides is opening to both our companies a dynamic future for servicing the most
demanding customers. At Ravne we always rely on our own positive judgement.
Our partnership with Raute means a very important step into the future. Success is
assured.” – Mr. Darko Ravlan, the General Manager of Ravne Knives.
PLYVISIONS
7
NEW TECHNOLOGIES AND SERVICES NEW TECHNOLOGIES AND SERVICES NEW TECHNOLOGIES AND
VENEER TAPING
increases yield and improves quality
IN TODAY’S CHALLENGING MARKET CONDITIONS, COST EFFICIENCY PLAYS AN IMPORTANT
ROLE AS PLYWOOD PRODUCERS
STRIVE TO ACHIEVE THE BEST
POSSIBLE YIELD AND CONSISTENT PRODUCT QUALITY.
MEASURES THAT WILL INCREASE
yield and improve quality are, therefore,
sought after in every phase of the ply­wood production process. In many cases,
improvements in yield and quality can
be achieved by making relatively small
changes in the production process. Such
changes are often very economical and
relatively simple to implement and offer
relatively fast payback.
The development of a veneer tape
application machine came from discussions between Mr. Ilpo Pasanen, a
plywood production specialist at UPMKymmene’s plywood mill in Säynät-
8
PLYVISIONS
salo, Finland, and Mr. Erkki Kauranen,
Raute’s Technology Manager in charge
of patching lines. Their discussion concentrated on ways to improve plywood
yield and quality, with both men being
of the opinion that the incidence of broken veneer during the various phases
of the plywood production process was
cause for considerable concern.
Veneer sheets are easily broken,
particularly when they became split and
cracked. Under such circumstances they
typically break in two. A good solution
to avoiding problems caused by split and
broken veneer is to use the time-proven
method of taping veneer in the early
stages of handling. While this is a good
solution, there are inherent problems
encountered when manually applying
tape to veneer. The process can be awkward, making it sometimes impossible to
achieve satisfactory taping results.
With a clear understanding of the
challenges involved in the veneer tap-
ing process, Mr. Pasanen and Mr. Kauranen set out to come up with a practical solution to this problem by working
together to design a machine that would
do the job efficiently with satisfactory
results.
TESTING WITH A VENEER
PATCHING MACHINE
It was the aim of both Mr. Pasanen and
Mr. Kauranen to develop and test the
tape application machine under actual
production conditions using a manual
patching machine. In this way they felt
the results of their work could be properly observed.
The first version of the tape applicator was a so-called rolling version
in which tape was first rolled onto the
surface of the veneer and then cut into
appropriate lengths. This process proved
to be too slow, however, and was discarded before being taken into the factory testing stage.
SERVICES NEW TECHNOLOGIES AND SERVICES NEW TECHNOLOGIES AND SERVICES NEW TECHNOLOGIES
Version two of the tape applicator
was the so-called revolver model because
the tape is guided above a circular form
divided into mechanical sectors. The
tape is pre-cut in lengths between the
sectors, after which the sector strikes
the tape with sufficient force for it to
adhere to the veneer’s surface. Results
were very positive. Its operational reliability, coupled with its operating speed,
made the revolver model tape applicator
suitable for further testing and it was
installed at the mill in January 2009.
OPERATION AND POTENTIAL OF
THE TAPE MACHINE
The tape applicator is engaged either
by foot pedal or a push button. An ergonomically designed model incorporating
a radio transmitter will also be available
shortly. The radio transmitter will be
incorporated into the operator’s safety
glove and will be activated by the operator pressing a button. The operator can
also use this function to change places
when working. A tape machine mounted
on an automated line is started directly
by the line’s control logic. This tape
applicator can also be adapted for use in
other lines as well, such as scarf-jointing,
composing and other patching lines.
Maintenance is fairly simple and the
device is easy to maintain. Tape bridges
are cleaned weekly using a solvent and,
where necessary, the tape cutter and
magnet is replaced. Cleaning takes less
than 10 minutes. Replacing the tape
roller will depend on the species of wood
being taped and the diameter of the roller.
The 75/120 mm diameter roller must be
replaced twice per shift when taping
softwood veneer, and once when taping
birch veneer. The time required to change
over a tape roller is less than one minute.
BETTER YIELD IN SEVERAL PLACES
Taping has been found to improve yield
in the following ways:
• By preventing cracks and splits in ve neer from growing larger and ensur­ ing that sheets hold together. This re-
duces the need for excess puttying at the finishing line and speeds up the delivery time of a finished panel.
• By ensuring that the patches placed in areas on veneer requiring multiple patches remain intact. The applica-
tion of tape to these areas ensures that double and even triple patches re­ main in place and so do not affect the
integrity of the veneer. This is especially
important where patches are applied
at the edges of veneer sheets.
• In subsequent production phases where veneer sheets may be subjected
to harsher handling, such as on the scarf-jointing, composing and lay-up lines. Here, the tape assists in saving raw material and improving product quality. In addition, fewer stoppages can be expected in the production process caused by equipment and ma chinery failures.
At the beginning of the development
work, 19 mm wide tape was used. However, it was determined that this width
IMPROVEMENTS IN YIELD
AND QUALITY CAN BE
ACHIEVED BY MAKING
RELATIVELY SMALL CHANGES
IN THE PRODUCTION PROCESS.
of tape did not adhere well enough to
the surface of the veneer, especially softwood veneer, where surface roughness
caused problems and there were difficulties with the tape staying in place. Also,
the ends of the tape tended to curl up
after application. To solve this problem
a tape with better adhesive qualities was
used, which required that the tape cutter be updated. The cutter has a coating
applied, which keeps it clean and sharp
for an extended period of time.
SIGNIFICANT POTENTIAL
This new veneer tape applicator has the
potential to be installed in a production
line supplied by Raute where its purpose will be to improve the quality of
the production process, or it can be supplied as a stand-alone unit. In whatever
application it is used, it has the potential
to improve the operational capability
of veneer patching, scarf-jointing and
composing lines. •
Text: Erkki Kauranen
Photos: Veli-Matti Lepistö
PLYVISIONS
9
CONTINUOUS DEVELOPMENT
guarantees competitiveness
RAUTE´S STRATEGIC GOAL IS TO BE A ‘FULL-SERVICE HOUSE’, THE GLOBAL LEADER
IN THE DEVELOPMENT OF TECHNOLOGIES AND SERVICES FOR THE PLYWOOD AND
LVL INDUSTRIES. FURTHER, IT IS OUR AIM TO ASSIST CUSTOMERS IN GENERATING
ADDED VALUE THROUGHOUT THE LIFE-CYCLE OF THEIR INVESTMENTS.
TO ENSURE THIS, we are continuously
developing and improving the technology and services we provide. Costefficiency is now more important than
ever, given the present difficulties of the
market and the global economic situa-
10
PLYVISIONS
tion. For most producers, current focus
is to improve existing production, rather
than building new. Good raw material
recovery, lower consumption of adhesives and other additives, as well as
savings in energy and labor costs are
important considerations in the present
market situation. Even small improvements in these areas can have very positive effects on profitability.
Over the past several years Raute
has invested significantly in develop-
ing products and services that offer
fast payback, enabling producers to
improve their production processes
step-by-step, rather than through single, large investments.
DEVELOPMENT WORK IS
ADVANTAGEOUS FOR BOTH
THE CUSTOMER AND RAUTE
Raute understands that customers’ mills
operate to very demanding schedules,
often around the clock. That’s why proactive maintenance and timely modernizations are important, ensuring that
the life-cycle of machinery is maintained and extended.
Raute products are designed such
that new technology can be applied to
existing machinery through the modernization of existing production lines.
With respect to productivity and quality, the results can be remarkable.
But, what does this mean in real
terms to our customers and how can it be
utilized in the daily operations of their
mills? The starting point for any development program is the understanding
that things can always be done better
and more effectively. This applies to both
machinery and production processes.
It is, therefore, of utmost importance
that shortcomings and inefficiencies
be recognized and turned into positive development opportunities, so that
producers can improve their competitiveness in the ever-changing business
environment.
FROM AUDIT TO DEVELOPMENT
Raute’s full-service concept incorporates a broad range of proven services
and products that can be utilized in
developing the profitability of our customers’ mills throughout the life-cycles
of their investments.
Optimum results are achieved by
first determining the target to be
attained and then undertaking a comprehensive analysis in order to determine
the proper output level. This applies to a
single machine, a production line or an
entire mill.
The correct solution is found in the
versatile range of specialized mill auditing services we provide. Audits are performed using field-proven methods and
the results are reported to the customer.
Recommendations based on these
results are typically divided into two
main areas: 1) recommendations regarding actions that need to be undertaken
immediately, including reasons for
doing so and payback calculations, and;
2) actions, which can include investments, to be taken over a longer period.
Customer mills are able to utilize these
auditing reports for planning and budgeting purposes for some years to follow.
Recommendations contained in
these audit reports usually include specific matters that focus on the development of production processes, the implementation of technology and the training
of mill personnel. Raute specialists are
able to define essential development
targets and recommend a diverse range
of development actions based on their
long experience in the plywood and LVL
industries globally.
MODERNIZATIONS IMPROVE EFFI­
CIENCY AND THE ENVIRONMENT
Raute´s mission is to develop and generate new innovations and products
that help our customers continuously
develop the competitiveness of their
own mills as well as that of the global
wood products industry. Our service
commitment covers the entire life-cycle
of the investment.
Over the duration of its service life,
Raute machinery can be adapted to suit
changing market needs. This can be achi­e­­ved in several stages. Naturally, regular, proactive maintenance and the use
of high-quality spare parts play signifi­
cant roles. Customers will find their
co­operation to be of most benefit when
they have a maintenance contract with
Raute.
Raute has developed, and continues to develop, modernization packages that utilize modern technology to
boost and improve the competitiveness
of older machines and production lines.
New technologies are implemented
most efficiently during planned mill
shutdowns. New in-line measuring and
monitoring technology, together with
advanced grading automation, help to
maximize production efficiency and
reduce the impact of production on the
environment.
IMPROVING THE COMPETENCE OF
MILL PERSONNEL
The training of mill personnel must
accompany the development of new
processes and technologies in order for
their benefits to be utilized quickly and
effectively. To ensure this happens, Raute
has developed a versatile range of modular training packages. They are a natural continuum to the training provided
during the startup of a production line.
Modular training enhances the skill sets
of the equipment operators and allows
mill personnel to take full advantage of
all features of the line.
In addition to these modular training packages, Raute offers tailor-made
training to meet the specific requirements of each mill. A training session
or program can be constructed based on
the results of a needs survey. Compiled
in conjunction with the customer, it is
designed to fit the specific needs of that
mill’s personnel.
REGULAR EVALUATION ENSURES
CONTINUITY
In order to maintain the continuous
development of our customers’ production processes and to sustain their profitability, it is important that they work
together with us to track the progress
of our planned cooperative actions and
how they are performing relative to the
value-added targets set. This is done
during ‘joint development days’, which
are held with contract customers annually and form the basis for the future
development of cooperation between
Raute and our customers. •
Text: Timo Kangas
PLYVISIONS
11
RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN
INSIGHT INTO
THE RUSSIAN
PLYWOOD INDUSTRY
RUSSIA’S SHARE OF THE WORLD’S FOREST AREA IS AROUND 22%
– CLOSE TO 800 MILLION HECTARES. THE AMOUNT OF WOOD RAW
MATERIAL IN THE FORESTS IS 80 BILLION M3, WHICH IS ABOUT 25%
OF THE WORLD’S WOOD RAW MATERIAL. THESE ENORMOUS WOOD
RESOURCES PROVIDE RUSSIA WITH MANY POSSIBILITIES FOR THE
FUTURE OF THEIR WOOD PRODUCTS INDUSTRY.
NEARLY 80 PERCENT of Russia’s wood
resources are situated close to Asia.
The resources are largely unutilized,
as annual growth is around 0.8 billion
m3 and annual logging accounts for
only 200 million m3 or so. The potential,
therefore, is huge making the future of
the wood products industry in Russia
appear very bright indeed.
In recent years, the Russian plywood industry has made substantial
investments in modernizing its production machinery and the processes of its
existing plywood mills. New greenfield
projects, however, have also been undertaken in the region and Russian plywood
has fast entered world markets.
12
PLYVISIONS
Positive financial development
prior to the current recession in Russia is one of the key factors that has
enabled the development of the country’s plywood industry. The banks have
been willing to grant loans to industrial companies and the wood products
industry has been seen as a good investment opportunity.
Russia has long experience in wood
processing and a strong scientific and
technical base. Fairly low production
costs have enabled profitable plywood
production. Affordable labor has been
available, and there are several woodfocused universities offering quality
education to meet future needs. There
is an abundance of raw material, even
though a relatively poor infrastructure
and lack of a good road network have
prevented the full exploitation of the
raw material resources to date. Energy,
on the other hand, is readily available
in many forms. There is also strong
political support for the wood products
industry in Russia.
FACTS AND FIGURES
Approximately 2.8 million m3 of plywood is produced in Russia annually
with 90% of production being situated
close to Europe. The main raw material
is birch. Most of the plywood mills still
produce 5x5 ft plywood for the domes-
RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA
tic market. New production capacity,
however, is mainly targeted towards the
global market and is made up of largesized plywood. Old production processes
are being modernized to fit the global
market plywood size standards.
There are more than 70 plywood
mills in operation, 30 of which can be
considered small mills. The ten largest
mills account for about 50% of the country’s plywood production. Although the
proportion of export sales is near 60%,
domestic demand is growing faster than
that of the export market. Sveza Group,
which owns 6 mills among the 10 largest,
dominates the production scene. Currently, there are two LVL mills in opera-
THE FUTURE
RUSSIA HAS LONG
EXPERIENCE IN WOOD
PROCESSING AND
A STRONG SCIENTIFIC
AND TECHNICAL BASE.
tion in Russia and all their production is
exported. It is the lack of local standardization of LVL products that restricts its
use in Russia.
Russia has a long tradition in the wood
processing industry. Wood is considered
a natural and ecologically sound material and its use is on the rise in Russia.
The use of wood in construction continues to see demand for this product grow
domestically in line with the growing
trend in residential construction.
The plywood industry in Russia is
profitable, thanks to low production
costs. New applications for the use of
softwood plywood and LVL are being
developed. Plywood is needed for building infrastructure, where the largest
application is overlaid plywood used
>>
PLYVISIONS
13
RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN
14
PLYVISIONS
N RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA
>>
as concrete shuttering. The transportation and shipbuilding industries also use
substantial amounts of plywood.
The furniture industry, too, has
shown signs of recovering from the
recession and it will consume a significant amount of plywood and veneer in
the future. It is estimated that the size of
the furniture industry will almost triple
by the year 2015.
All in all, the use of wood products
will increase. Renewable wood material is seen as an ecological and safe
choice. Export opportunities will grow
as export regulations further relax. Furthermore, Russia’s plans to develop the
forest sector will help promote the realization of investments. •
Text: Molli Nyman and V.A. Prohorov
Photos: Veli-Matti Lepistö
The largest plywood producers in Russia 2010
COMPANY
GROUP
Syktyvkar Plywood Mill LLC
Permsky Plywood Mill LLC
Sveza
CJSC Fankom
LOCATION
PROVINCE
WOOD SPECIES
ESTIMATED
CAPACITY,
m3/a
Syktyvkar
Komi
Birch
190 000
Uralsky
Perm
Birch
180 000
Verkhnyaya Sinyachikha Sverdlovsk
Birch (80) and pine (90)
170 000
Ilim Bratsk DOK LLC
Ilim Timber Industry Bratsk
Irkutsk
Pine (120) and larch (20)
140 000
CJSC Zheshart Plywood Mill
United Panel Group Zheshart
Komi
Birch
120 000
JSC Fanplit 1
Sveza
Kostroma
Kostroma
Birch
110 000
JSC Fanplit 2
Sveza
Kostroma
Kostroma
Birch
110 000
JSC Ust-Izhorsky Plywood Mill
Sveza
St. Petersburg
St. Petersburg Birch
110 000
CJSC Krasny Yakor
Slobodskoi
Kirov
Birch
110 000
CJSC Arkhangelsky Plywood Mill
Novodvinsk
Arkhangelsk
Birch
105 000
PLYVISIONS
15
RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN
RAUTE IN RUSSIA:
From war reparations to solid cooperation
Raute and Russia share a common history that began during World War I with the Soviet era. Raute began manufacturing plywood machinery in the 1930s and during WWII
focused on the manufacture of munitions. Between 1944
and 1952 Raute supplied approximately 1,200 machines as
part of Finland’s war reparations to the Soviet Union. Once
the payment of war reparations was completed, the
two nations moved towards
cementing bilateral trade,
which saw Finland, and
Raute in particular, supplying machinery and expertise
to the Russian wood products industry.
In the 1960s, Raute made
the move from manufacturing stand-alone machines for
wood processing to manufacturing complete production lines and mills. Raute
delivered the first complete
plywood mill to Bratsky
(Bratskiy LPK) in 1970.
The Soviet Union (1922–
1991) was, in its day, the
fourth biggest plywood pro­ducer in the world, after
the U.S., Japan and Canada.
Seventy-four plywood mills
were in operation, however,
machinery operated at a low
capacity level and the pro­duction processes were
highly mechanical with little automation. As a result, the costs
associated with production were many times those of the U.S.
and Canada.
Beginning in the 1970s, the Soviet Union’s plywood mills
began to be modernized and refurbished, with new mills
being systematically built from that time through the 1990s.
The upgrading and general revitalization of plywood pro-
16
PLYVISIONS
duction machinery was made easier by the clearing system
between the Soviet Union and Finland concerning the trading
of goods and methods of payments.
Raute delivered a wide range of machinery and complete
production lines to the Soviet Union, such as individual lathes
and complete green veneer peeling lines, veneer drying lines,
composing and jointing
machinery, plywood presses
and trim saw lines, as well as
all required spare parts and
testing equipment.
The majority of veneer
being produced at Russian
plywood mills these days
is produced using Raute
peeling lines. Current cooperation is based to a large
degree on the modernization of existing production
equipment and on Raute’s
technology services. There
is a clear need to increase
local know-how and to finetune existing production so
that it continues to become
more efficient and profitable. Along with the growth
in demand for wood and
plywood, the building up of
new production capacity will
provide the Russian plywood
industry with a greater competitive edge over other
countries.
Raute’s Moscow office was established in 1992. Raute
Service LLC, which focuses on maintenance services, modernizations and training, began operations in St. Petersburg in
2005. •
Text: Molli Nyman and V.A. Prohorov
Photo: Eino Mäkinen
RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA
New Greenfield project in Russia
OOO VYATSKIY FANERNYI
KOMBINAT (VFK) IS LOCATED
IN RUSSIA IN THE CITY OF
KIROV (FORMERLY VYATKA) IN
THE INDUSTRIAL REGION OF
NOVOVYATSK LPK. TWO FIBREBOARD MILLS, A SAWMILL AND
A WOOD PRODUCTS PLANT ALL
OPERATE AT THE SAME INDUSTRIAL SITE. THE PLYWOOD MILL
WAS STARTED UP IN JANUARY
2009, FOLLOWING A YEAR-ANDA-HALF-LONG CONSTRUCTION
PERIOD. THE BASIS FOR THE
PROJECT ITSELF, HOWEVER,
HAD ALREADY BEEN LAID TWO
YEARS EARLIER IN 2007.
CONSTRUCTION PLANS for the new
plywood mill called for a facility that
would produce 90,000 m3 of large-sized
birch plywood panels annually. Approximately two-thirds of that amount was
slated to be overlaid with paper-based
protective films, which would make it
suitable for use as concrete formwork
in construction and for the manufacture
of truck beds and other vehicle components used in transportation. Close to
90% of production was to be earmarked
for export, with the rest being supplied
to Russia’s domestic markets.
Financing of the project was provided by the forest industry holding
company ZAO Investlesprom, which
has been increasingly investing in forest industry projects in close coopera-
tion with OAO Bank Moskvy. Financing
was approved for construction of VFK
in December 2006. The total value of the
investment exceeded 3.2 billion rubles,
or approximately 80 million euros.
CHOOSING THE SITE AND
SUPPLIERS FOR THE PROJECT
Many factors were behind the choice
of Novovyatsk as the site for the mill,
the most significant being the availability and adequate supply of raw material. Forest resources in the Kirov area
are approximately 800–900 million m3,
of which birch makes up more than 340
million m3. Only one other plywood mill
operating in the area, Krasnyi Jakor, utilizes the birch plywood logs harvested
>>
PLYVISIONS
17
RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN
>>
annually in the Kirov area. In addition,
it was possible to use existing municipal engineering in the area as well as
Novovyatsk’s LPK infrastructure, which
included a rail link.
All of the contractors involved in the
planning and construction of VFK were
chosen on the basis of a call for tenders.
The primary design company selected for
the project was OOO Kostromapromproekt. A contract was subsequently signed
in April 2007 for “
A project to build a
mill with the capacity of 90,000 m3 of
large plywood annually in the city of
Kirov in the area of Novovyatsk.”
Raute was selected as the primary
machinery supplier from among 11 foreign companies, three of which offered
mill-scale deliveries – one an Italian
company, one from Japan and Raute.
18
PLYVISIONS
APPROXIMATELY 90%
OF THE PLYWOOD
PRODUCED IN RUSSIA
IS MADE ON MACHINERY
MANUFACTURED BY RAUTE.
The machinery and equipment delivery
contract between OOO VFK and Raute
Corporation was signed in November
2006. Machinery was delivered during
2007 and 2008.
In early January of 2009, VFK was
started up and already in the same year
produced 47,000 m3 of plywood. In 2010,
monthly production was around 7,500
m3 of plywood with the mill still able to
operate at 90% of rated capacity, despite
the generally low economy.
The start-up of the mill was aided
by a number of factors, such as the timing of the investment, the correct choices
of technology and machinery, flexible
production, the possibility to produce
two different sized panels and the professional skills of the staff involved.
RAUTE HAS SOLID KNOW-HOW
AND REFERENCES
Raute was selected as the primary
machinery supplier for the mill for a number of reasons. Raute has more than 100
years’ experience in the manufacture of
machinery for the wood products indus-
RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA
try and is the biggest company worldwide specializing in mill-scale deliveries
of this kind. Over the past 25 years, too,
Raute has developed new technology,
such as six new lathe models, plywood
lay-up lines, and drying and grading line.
Approximately 90% of the plywood
produced in Russia is made on machinery manufactured by Raute. All the
major producers in Russia have Raute
machinery in their mills. There are also
many single processing lines and standalone machines manufactured by Raute
in operation in different plywood mills
throughout the CIS countries. These
strong references, together with Raute’s
wide range of technology and our ability to serve our customers in the Russian
language were also important factors in
our securing this important project.
EFFICIENCY AND CERTIFICATION
PLAY AN IMPORTANT ROLE
Raute’s machinery is efficient and highly
automated. The two Smart Peel peeling lines included in the contract, for
instance, can peel the required amount
of veneer to make 90 to 100,000 m3 of
plywood annually. As a turnkey supplier
Raute also bears responsibility for the
capacity of every line and for the compatibility of the lines.
One of the decisive factors behind
Raute receiving the machinery order was
that its products are certified for operation in Russia. Raute carries the Russian GOST standard certification, which
means Raute machinery can be used to
manufacture plywood that complies
with the ISO 9001 quality standard. It
also carries the CE stamp for plywood
deliveries to EU countries, as well as the
DIN 68705, part of the 3BFU100 (Germany) permit for using the products in
construction.
In addition, Raute provides an
extensive range of services, such as
maintenance, spare parts and personnel
training. This versatile service offering,
combined with Raute’s commitment to
producing the most up-to-date technology available for undertaking equipment modernizations and upgrades,
ensures that the competitiveness and
profitability of the production process
will be continuously developed throughout its entire life cycle. •
Text: Molli Nyman & V.A. Prohorov
PLYVISIONS
19
RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN
Vyatskiy Fanernyi Kombinat
invests in new birch plywood mill
ACCORDING TO THE GENERAL MANAGER OF
RUSSIA’S VYATSKIY FANERNYI KOMBINAT (VFK),
MR. JURIY SHADRIN, THE IDEA TO INVEST IN A
MILL TO PRODUCE BIRCH PLYWOOD WAS SIMPLY A FLUKE THAT CAME ABOUT WHEN INVESTORS INVESTLESPROM ACQUIRED KDP “NOVAYA
VYATKA”.
“BEING THAT KDP WAS A PRODUCER of MDF, Mr. Juriy
Valevin, the then General Manager of KDP, got the idea to produce large-sized plywood and, by doing so, develop the company’s industrial business sector, “ said Mr. Shadrin.
Located in the Kirov region of Russia, financial support
for the project came from Bank Moskvy and in May 2007
construction work on the project began. Installation of the
machinery and equipment began as early as October that
same year and took 12 months to complete. In the section
of the building where heating was available the machinery
was installed, while in the unheated section of building cons­
truction work was carried out. The first veneer was pro­du­­­­­c­ed in July 2008 and the first batch of plywood in November
of that same year. A month later the entire mill was in pro­
duction.
“We are especially proud of the fact that our mill, which is
certainly one of the most modern plywood mills in the industry,
was built up from “zero” to near full production in just eighteen months,” said Mr. Shadrin.
20
PLYVISIONS
In April 2009, installation and fine-tuning of the panel
coating line were completed. Today, the mill produces approximately 7,800 m3 of plywood per month, which satisfies planned
capacity of 90,000 m3 annually. A percentage of production
will be FSF-stamped water-resistant product. Product dimensions will be 1,220 x 2,440 mm; 1,250 x 2,500 mm; 1,500 x 3,000
mm, and 1,525 x 4,050 mm in thicknesses ranging from 6.5 to
30 mm.
Mr. Shadrin explained that Raute was chosen as the primary supplier for all plywood machinery based on the company’s ability to provide an overall solution for the entire production chain, starting from raw material handling and cutting,
through peeling, drying, veneer handling and pressing. Raute
even supplied knife sharpening equipment and equipment for
packaging the finished product.
“We felt that Raute was the only supplier who could have
a positive impact on the construction period of the mill and
make it easier to organize the process, familiarize staff with
their work, and provide the correct level of technical maintenance and fine-tuning for the machinery,” said Mr. Shadrin.
“In fact, the latest technology and machinery available
from Raute has been installed in VFK’s new birch plywood
mill and it has proven to be very good. And, although the warranty periods for machinery have already expired, Raute has
continued to be involved in the operation of the machinery and
has been active in helping us solve the inevitable “bottlenecks”
that are typical of start-ups such as this. We are very satisfied
with both the technology provided by Raute and their operation in supporting us,” Mr. Shadrin added. •
RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA RAUTE IN RUSSIA
LESDREVMASH 2010:
A solution for every budget
LESDREVMASH IS A MAJOR
INTERNATIONAL EXHIBITION
AND TRADE FAIR HELD IN
RUSSIA EVERY TWO YEARS.
ITS FOCUS IS ON MACHINERY,
EQUIPMENT AND TECHNOLOGY
ASSOCIATED WITH THE WOOD
PRODUCTS INDUSTRY.
In support of this theme, Raute’s
R&D Department had devoted considerable effort prior to Lesdrevmash 2010
in the development of new technological
solutions that combine years-long experience with the latest innovation. At the
exhibition we introduced one of these
new products to the Russian market –
the new RautePro XY charger, which
offers plywood producers the opportunity to quickly and easily update their
outmoded block charging and centering
systems. Read more about this new product in PlyVisions, page 4.
Raute wants to express our thanks
to the many industry people and customers who visited our stand at Lesdrevmash 2010 and we look forward to
fruitful cooperation in the future. •
Text and photo: Ossi Lahtinen
FIRST HELD IN 1973, Lesdrevmash took
place this past year in Moscow and ran
from September 27th to October 1st.
Over 500 organizations and companies
from 23 different countries took part.
At Lesdrevmash 2010, it was clearly
evident that Russia is coming out of
the financial crisis that has plagued the
world economy in recent years and that
the foundation for renewed growth is
being laid. Large delegations of Raute’s
customers were in attendance and it was
quite usual to see senior members of our
customers’ staff, including Presidents
and CEOs, at our stand. The seven wood
products professionals representing
Raute were kept constantly busy as customer after customer presented themselves at our stand eager to hear about
our the new products and services Raute
had on offer.
Raute’s theme for Lesdrevmash 2010
was “For every budget Raute has a solution”. This theme emphasized that Raute
not only provides the most advanced,
technologically complex and, therefore,
potentially expensive range of machinery and services, but that we also offer
products that serve the individual
needs of every customer, based on their
requirements and the budgets they have
available.
PLYVISIONS
21
Italian producer is
up to the challenge
THE ITALIAN PLYWOOD AND BLOCK BOARD PRODUCER, SAN GIORGIO SPA,
CELEBRATED FORTY YEARS IN BUSINESS IN 2009. THEY ARE A SMALL,
FAMILY-OWNED PRODUCER WHOSE EFFORTS ARE INSPIRED BY RESEARCH,
A CONTINUOUS DEVOTION TO QUALITY IMPROVEMENT AND AN UNWAVERING COMMITMENT TO CUSTOMER SERVICE.
PRESIDENT MASSIMO MASSONI sees
the success of his company as being
rooted in its ability to provide a flexible
product mix, supported by what he calls
a customer care approach.
“We operate in a challenging market and we must be flexible in the products we provide. This means offering
special panel sizes and small batches,”
he said, adding that San Giorgio is able
to do so by understanding the needs of
their customers and finding solutions to
their specific needs.
He went on to say that, “It is also
important that we remain customer
oriented, since we do not compete in
the large-scale commodities business.
Personal contacts and assurances are
a key part of the way San Giorgio does
business. It helps, too, that we are centrally located with respect to our customers.”
22
PLYVISIONS
Situated in Villanterio near the
historic city of Pavia, Italy, the Massoni family’s company employs a staff
of forty-five, including Massimo’s wife
Monica and, since September 2008, son
Nicola, who oversees certain technical
and commercial aspects of the day-today running of the company.
San Giorgio produces both poplar
and birch plywood, as well as blockboard. Poplar products are produced
from local wood, while birch veneer is
produced at the mill in Shatura, Russia,
which the Massoni family owns jointly
with their Russian partner. Located 120
kms east of Moscow, the Shatura mill
has been operating since 1997 and is
under the management of San Giorgio’s
Franco Stilio, who has been at the mill
since it opened. The mill operates with a
staff of fifty and produces about 17,000
m³ of birch veneer annually.
“We offer a specialized range of
products for the furniture, transportation, flooring and laser plywood industries,” stated Massimo. “In 2009, San
Giorgio produced 10,000 m³ of plywood
and 6,000 m³ of blockboard, which was
sold to customers in Germany, Austria,
Spain, the Netherlands and the U.S.A.
Our domestic customers bought about
one-third of our production.”
INVESTING DURING
DIFFICULT TIMES
Massimo Massoni understands about
the need to invest in order to succeed.
Over the past decade his company has
undertaken significant capital expenditure on numerous occasions, often
selecting Raute as the primary supplier.
“At the beginning of this new millennium it was very difficult to be in the
plywood industry. That’s when we took
AT THIS MOMENT THE OVERALL PLYWOOD MARKET SITUATION IS VERY CHALLENGING,
BUT I AM TRUSTING IN THE FUTURE.
the decision to develop our business by
investing in our factory. This meant widening our scope of production by making
larger panels so that San Giorgio would
be in a stronger position when business
improved,” said Massimo. “I knew the
Raute company and some of their sales
and technical staff and I found the solutions they offered were suitable and met
my needs. I can honestly say that my
decision to work with Raute was the
correct one.”
The investment made by the mill
in 2001 included a Raute scarfing line,
semi-automatic layup line complete with
glue spreader and a big size 10-opening
pressing line. Fast forward to 2008 and
San Giorgio’s decision to again choose
Raute as their veneer composer and glue
spreader supplier.
Said Mr. Massoni, “During the
period surrounding our previous investment project with Raute, we learned
much about new production technology. It was a well managed project supported by quality machinery and a high
level of technical service, both during
and after the warranty period. This convinced us to go with Raute on this composer project.”
San Giorgio’s project team worked
with Raute’s technology people to find
the best technical solutions, as well as
the optimum location for the new line in
the mill. According to management, the
new composing line has provided better
raw material recovery as well as providing flexibility in veneer sizes that will
improve San Giorgio’s ability to serve
their customers.
“While the composer was being
installed, we were undertaking other
investment projects in our mill, including installation of a new 3 MW boiler.
I am extremely pleased that we were
composing veneer only two weeks after
starting the installation,” stated an obviously satisfied Massimo Massoni.
“I am pleased, also, that the composer was so thoroughly tested at Raute’s
Nastola factory before shipment and
that our control specialist, Mr. Angelo
Bascape, was able to participate in the
testing and disassembly at Raute’s factory. This ensured that everyone knew
what to do once the machinery arrived
at our mill and helped to ensure that the
installation and start-up went smoothly.
Many thanks belong to Raute’s professional project and start-up crew and to
our own personnel,” added Massimo.
A further investment undertaken by
San Giorgio included the start-up of a
lay-up and pressing line in April 2009,
which will enable the mill to produce
film-faced plywood and special-sized
white plywood and blockboard – 5+
meter long and 6+ meter long respectively. New laboratory testing equipment
was also supplied with the delivery. San
Giorgio now employs a full-time laboratory engineer who is charged with the
responsibility of product testing and the
investigation and development of new
products.
LOOKING AHEAD WITH A
POSITIVE VIEW
Massimo Massoni is a practical and pragmatic company owner. “At this moment
the overall plywood market situation is
very challenging, but I am trusting in
the future. For instance, ecological issues
are very important today and we have
to work hard to promote the ecological
aspects of Italian poplar plywood – its
rapid renewal, its strength and its very
light and white colour that make it the
premier quality poplar in Europe. These
very positive attributes will assist Italian producers of poplar plywood to better serve their customers and improve
the Italian poplar plywood industry as
a whole.”
As to the future, Massimo stated
positively that he has specific expectations for Raute to meet.“Very soon it will
be time to begin planning investments
connected with improvements in raw
material recovery and panel quality.”
In the meantime, however, this Italian plywood producer will fine-tune
the working of his successful business
in order that it is in the best possible
shape when the full power of the plywood industry is restored. •
Text: Sauli Salmela
Photos: Veli-Matti Lepistö
President Massimo
Massoni (left) and
his son Nicola
Massoni.
Composed poplar
veneer sheets.
PLYVISIONS
23
EXPERTISE IN PLYWOOD AND LVL TECHNOLOGY
www.raute.com
SPARE PARTS
= AVAILABLE ONLINE, ON TIME, ON BUDGET
24/7
To keep your production running at peak efficiency, Raute
provides competitively priced spare parts, maintenance and
modernization services that are available online, on time
and on budget. It’s all part of our commitment to provide
support throughout the life-cycle of your investment.
 Register now at www.service.raute.com and get a 10%
discount on your first online spare parts order! This
service is now available also in the U.S.A and Canada.
TECHNOLOGY

UPGRADES

MODERNIZATIONS

SPARE PARTS

MAINTENANCE

TRAINING