The mechanisation specialist Kallfass was able to successfully commission the first system at Robeta Holz in Milmersdorf, Germany, at the beginning of January.
What was initially planned as a more straightforward restacking plant for driedsawn timber has become a real gem, which has eliminated a production bottleneck at Robeta Holz.
“Previously, we also had to re-sort and stack the dry goods at our sorting plant,” said Christian Rockel, production manager at Robeta Holz. “Since the demand for dry goods has risen steadily, re-sorting was only possible with considerable extra hours – sometimes the system also ran on Saturdays or we started on Sunday evening.”
This bottleneck had to be removed and so those responsible for the sawmill in Uckermark, Germany, approached Kallfass, Baiersbronn-Klosterreichenbach, Germany, to make enquiries.
“Kallfass has a very good name in the industry,” said Mr Rockel. “We have also been approached by pallet manufacturers who said: ‘If you cut the sawn timber with a Kallfass system, then we’ll buy from you’,” he said. He is referring to the reputation of high accuracy of the mechanisation specialist’s multiple cross-cut saw.
COMPLETE PACKAGE
“Originally, a smaller restacking system was envisaged,” recalled Kallfass project manager Enrico Goldhahn. “However, during the discussion it turned out that Robeta wanted to be more flexible and we ultimately delivered a fully comprehensive system with some technical refinements.”
Among other things, Robeta Holz also paid attention to ergonomics: All system components are easily accessible and the walkways are particularly wide. This results in the best working conditions for the employees.
“We had enough space for the planning and for the system, so we optimised the process. A great reference project has been created,” said Mr Goldhahn. His colleague Matthias Link, responsible for sales at Kallfass added: “All the responsible people, such as electricians and locksmiths, were involved in the project right from the start. That made the co-ordination much easier.”
Robeta Holz built a new hall for the Kallfass system and the assembly work started on September 6, 2022. In January this year the trial operation began. As mentioned, the new restacking equipment is intended for dry goods. However, Robeta Holz can also use this equipment for fresh sawn timber. The system is designed for cross-sections from 16 x 75mm to 125 x 200mm with a length from 0.8 to 6.3m.
CLEAN SEPARATION
The sawn timber feed offers space for several packages. “For a higher output, the system is equipped with two conveyors,” said Mr Link.
The hydraulic tilt destacking unit has pneumatic pawls for better stick separation. “The pine is slightly tacky – with the slight push, however, the sticks detach better from the lumber layers,” said Mr Goldhahn. The sticks are collected separately and spaceoptimised in stanchions.
After separation and downstream of an alignment roller conveyor, the workpieces reach the assessment station, where an employee performs a final quality check. The subsequent Tongloader® cycles the boards and planks – regardless of the cross-section – onto the downstream chain conveyor at a rate of up to 120 cycles per minute. The Tongloader® is equipped with an anti-twist device.
“This ensures that cross-sections that are approximately square are not transported on edge,” said Mr Goldhahn.
The workpieces pass through the Brookhuis moisture measurement system in a transverse run-through. “Pieces that don’t fit are ejected, as are the rejects,” said Mr Link.
The respective boards drop down through a sorting flap onto a belt below and arrive at two points on a table where they can be removed separately.
Subsequently, the good parts move through the Kallfass multiple cross-cut saw. The latter is equipped with five saw aggregates – four of which can be positioned automatically.
ADJUSTABLE MAGAZINES
The stacker has a capacity of up to 12 layers per minute. Kallfass has further strengthened this stacker for large wood dimensions. The system has eight double magazines for stacking sticks and sticks being disposed of.
“The magazines can be positioned automatically,” explained Mr Link. “This also allows more sticks from a magazine to be placed on the sawn timber layers if required. The motorised adjustment allows the sticks to be positioned closer to the cutting edge. The minimum distance corresponds to a stick width plus 10mm. We have also equipped the existing sorting system with these new stick magazines.”
The finished packages arrive at the Kallfass automatic foiling station.
“This station can also be equipped with unfolded film up to 3.6m wide,” said Mr Link. The wrapped packages then enter the Fromm package press with two squared timber magazines, and are strapped and transported out of the hall through a high-speed door. The parcels are transferred to the pick-up point for the stacker via an angular transfer device.
“Kallfass has done a very good job,” said Mr Rockel. “The co-operation was impeccable – the handling of the installation was also smooth due to the good planning. We can now respond to customer requests much faster and have brought the working hours back to a normal level. The system is operated by three employees and one forklift operator. The output of the system is very high, consequently requiring only a single-shift operation. I am happy every day about the successful project.”
