Western Forest Products
Angling for speed
Physical limitations required inventive thinking to deliver the
desired result. “We were really happy with the layout we came out
with. We got more out of the design than we expected.”
This unique layout design called for the new trim line equipment to be
aligned along an incline at a steep angle of 13.5°.
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Millwide INSIDER | ISSUE 2 - 2012
Ingenious is the word that comes to mind with the
unique layout design that called for aligning a new
positioning transfer, Multi-Track Fence, multisaw Lineshaft Trimmer and extended ending roll
transfer, on a 13.5 degree incline. The results of
the new line designed with high speed capability,
are pure gravy.
During the boom years of 2005-2006, Western
Forest Products (WFP) at Cowichan Bay, BC,
invested in major upgrades to its sawmill with
equipment from USNR’s Salmon Arm (Newnes)
division. Then came the inevitable end to the up
cycle and further investment was put on hold. After a
strategic company restructuring followed by a record
of positive returns, funding became available in mid2011. The mill turned its sights to the planer mill to
begin to bring it up to date, reduce unit costs and
make the mill more competitive and resilient through
the next cycle.
The Cowichan Bay mill is located in the
southeastern region of Vancouver Island, off the west
coast of BC. It manufactures dimensional lumber
from primarily hemlock that is processed, graded
and sold green, and marketed worldwide. The mill’s
capacity is around 200 mmbf and it employs 120
workers over 2 shifts.
DESIGN INGENUITY YIELDS BETTER THAN EXPECTED RESULTS
Phased modernization
Roger Perry is mill manager and he explained
the reasoning behind this project. “We did a very
extensive sawmill upgrade a few years ago. With
the market turndown we had to wait to upgrade the
planer. This is the first phase of more extensive
modernization that we’ve planned for the planer mill.
We were looking to replace the obsolete trimmer
setup that we had, and build in enough capacity for
future upgrades.”
The overriding goal for the project was to allow the
mill to increase its speed and throughput. With this
phased approach to updating its planer line the mill
had to ensure the equipment selected in this phase
would work for it in the longer term once the whole
line was brought up to contemporary standards. WFP
looked at several trimmer and fence designs before
“We were looking to replace the obsolete
trimmer setup that we had, and build in
enough capacity for future upgrades.”
“With where we are at now we think
we can probably hit 160 (lpm) anyway
because that extended incline gave us a
longer ending roll.”
choosing to work with USNR, selecting a Newnesstyle multi-saw Lineshaft Trimmer and Multi-Track
Fence. Roger related, “I think the Multi-Track Fence
is probably the best one out there, and we were quite
intrigued. We have a Newnes trimmer in our sawmill.
We looked at a number of other trimmers and we are
happy with the one in our sawmill, and compatibility
with parts is also good.”
Coming up with the layout was one of the biggest
hurdles the project team had to resolve. Space
was an overriding issue, and as Roger says, “It is
difficult to retrofit a mill. We had some space issues
and some physical hurdles to overcome.” Because
of the distance from where boards come out of the
planer to the sorter infeed, there is not enough
room to do everything on a level transition and
GRADE STAMP
have a stable incline to get up to the sorter infeed
elevation. The idea to put the new equipment on an
incline was “hatched” over time. The team reviewed
a number of layout options and the incline made the
most of the available real estate, plus afforded some
noteworthy benefits.
Configuration’s “hidden gems”
Roger explains the ingenuity of the design. “By putting
it on that type of an incline we were able to extend
the ending rolls 6’ longer than planned, and that
really allowed us to increase the throughput speed,
which is fantastic. We anticipated putting in a trimmer
that would allow us to run 120 lpm, and at a future
point in time having to put it into a different layout
configuration to get to 160 (lpm). With where we
are at now we think we can probably hit 160 anyway
because that extended incline gave us a longer ending
roll.” And with solid steel support for the equipment
it can readily be reconfigured to a flat arrangement
in the future when the rest of the line is updated. On
the overall design, Roger comments, “We were really
happy with the layout we came out with. We got more
out of the design than we expected.”
Extending the ending roll (now 14’-6”) allows
running at faster speeds because it extends the
available time for the trimmed boards to travel
NEW DESIGN LAYOUT
MULTI-SAW TRIMMER
W/ PET SAW
ENDING ROLL TRANSFER
MULTI-TRACK FENCE
EXISTING GRADING TRANSFER
EXISTING NEWTRONIC
LUG LOADER
13.5˚ STRUCTURAL STEEL
AND EQUIPMENT SLOPE
The new layout required significant changes
to the material flow to facilitate increased
throughput from the system.
OLD LAYOUT
ISSUE 2 - 2012 | Millwide INSIDER
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“It’s (Multi-Track Fence) an amazing
thing to watch. We think the technology is
unique. It opens up a lot of possibilities for
us in our trimming. Our trimming accuracy
is much improved.”
The Multi-Track Fence is fitted with 13 lumber position
paddles and allows for 24” of infinite positioning.
to lumber line ahead of the grade stamp and
sorter infeed. The original ending roll transfer
accommodated ending rolls that were a mere 8’-0”
long, resulting in significantly slower lug speeds
than the mill now desired.
Roger is impressed with the new Multi-Track
Fence. “We haven’t really used it to its potential
because of constraints on either end (of the
line). It’s an amazing thing to watch. We think
the technology is unique. It opens up a lot of
possibilities for us in our trimming. Our trimming
accuracy is much improved, and the P.E.T. in the
trimmer also contributes to that.” The Multi-Track
Fence is fitted with 13 lumber position paddles and
allows for 24” of infinite positioning.
Roger is also happy with the trimmer that was
selected. “It’s great, the same as in our sawmill.
We’ve had that one for 6 years and it just runs.
We’ve had no issues at all.” The new trimmer
accommodates 17 saws including a precision end
trim (P.E.T.) saw, and is fitted with extended as
well as standard holddown shoes for processing
the maximum piece size of 4” x 12” x 26’-0”.
Quick couplings with one spare belt and hanger per
coupled lineshaft section allow speedy belt changes.
Saw ladders and mounts are easily relocated for saw
spacing changes, and are designed for 18” diameter
saws. Cushioned air cylinders actuate to lift and
lower the saws. The trimmer is completely preplumbed for automatic lubrication.
Roger related that the installation and start-up
proceeded very well, and he appreciates the ongoing
support he has received for this and previous
projects. The mill has enjoyed a good relationship
with USNR’s Salmon Arm division in the past, having
completed the major upgrade to the mill’s sawmill
“It’s great (Lineshaft Trimmer), the same
as in our sawmill. We’ve had that one for
6 years and it just runs. We’ve had no
issues at all.”
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Millwide INSIDER | ISSUE 2 - 2012
“The biggest improvement we’ve seen
... is very much improved continuous
operation. We don’t have the starts and
stops we had before. We’re also seeing
much, much better trim quality than we
had previously.”
The incline allowed for extending the ending transfer and ending rolls, in turn accommodating
higher speeds and throughput.
several years ago. During the current project the mill
was closed for one week in mid-November 2011 for
installation and start-up.
Running strong
Roger expressed that the incline configuration for
this design presented the greatest challenge, but
also returned better than expected results. “We’ve
got a bit more flexibility in terms of our length
outturn. We put more saws into this (trimmer saw)
box than we had in our other box. The biggest
improvement we’ve seen, outside of speed
constraints on either side of the saw box which
we’ll address in the future, is very much improved
continuous operation. We don’t have the starts and
stops we had before. We’re also seeing much, much
better trim quality than we had previously.” Roger
also said the mill reached a budget shift on the
second shift after start-up, and its fourth shift was
a record!
Mill personnel involved with the project included
Randy Brown, maintenance superintendent who
managed the project, and Tim Burnham who recently
joined WFP as a maintenance superintendent.
Also very much involved were Steve Smith, the
mill’s head electrician, who was responsible for
the controls portion, Randy McCullogh, the planer
chargehand, helped configure the final design,
and the rest of the planer personnel had a hand in
bringing the project to life.
Now that the trimmer area has been updated WFP
will turn its attention to the rest of the planer line.
The company’s ownership has announced aggressive
capital investment plans for the near future. WFP’s
facilities are under review for the most suitable
allocation of future capital investment. Roger
comments, “The number one opportunity on our site
is to increase the throughput and performance in our
planer mill. We’re looking at increasing the range of
products we can run in our planer mill, and scanning
upgrades and throughput improvements in the
sawmill as well. We’ve got lots on the go.”
The new trimmer accommodates 17 saws including a precision end trim (P.E.T.) saw, and is fitted
with extended as well as standard holddown shoes for processing the maximum piece size of
4” x 12” x 26’-0”.
Scan this QR code
with your smart
phone to view a video
of the Multi-Track
Fence operating at a
mill in BC.
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Millwide INSIDER | ISSUE 2 - 2012