Expanding the laminated timber production

Since 2005, Kirnbauer Holzindustrie's laminated timber production has been based in Ternitz. The factory outputs about 45,000 m³ of glulam and duo beams every year for the domestic market and exporting. When building the site 13 years ago, manager Franz Kirnbauer was actually also planning on producing KVH. Soon, however, glulam proved more profitable on this line. "KVH and large duo beams must be produced on a separate line," Kirnbauer explains. The opportunity presented itself to expand the premises in Ternitz – in the middle of an industrial park – to 85,000 m² so Kirnbauer decided to invest into a second production line that was specifically designed for duo beams and KVH. For this reason, he hired Kohlbacher from Langenwang to build two new halls one of which houses the production line while the other serves as loading hall. Operation in Ternitz was launched in September and the two-shift operation followed in January already.

Kirnbauer chose the following main suppliers for the new plant: The entire mechanization as well as the Lignopress press for producing duo and trio beams as well as glulam, if need be, come from H.I.T. from Ettringen/DE; Ledinek, Maribor/SL, delivered the cross-cut saw, the finger-jointing line as well as two planing mills. The master computer was supplied by Bidac, Kaltern/IT, the exhaustion system by Scheuch, Aurolzmünster, and the adhesive application by Oest, Freudenstadt/DE. "We already relied on H.I.T. during the reconstruction of our existing plant two years ago. The collaboration was impeccable. I particularly like their plant engineering and material-friendly transportation," Kirnbauer explains and adds: "Ledinek delivers robust machine engineering and offered us a great cost-benefit ratio. Furthermore, the proximity to Maribor is an advantage if we ever need repair parts at short notice."

In general, the factory is supposed to be operable with only four employees. The aim is to run production between the finger-jointing system and the laminated timber press unattended.

Thought-out procedure

H.I.T.'s part in the process starts with the feed-in of lumber packages: A fork-lift operator provides the required dimensions. A screen shows which package (type of wood, cross-section) he is to provide next. A vacuum lift de-stacks the lumber stack layer by layer and feeds the pieces to the employee who marks defects (such as knots or cracks). In cross transport another wood moisture measurement by Gann as well as a classification measuring follow. Boards that don't fit can be sorted out.

The H.I.T. mechanization conveys the boards for trimming via cross transport to the X-Cut cross-cut saw from Ledinek. Remaining packages can be discharged from the procedure and provided at a separate spot so that the fork-lift operator can pick them up at the next opportunity. In cross transport upstream of the cross-cut saw there furthermore is an extra buffer. "This is where goods of particularly high quality can be retained for processing at a later time," H.I.T. manager Franz Anton explains during the visit.

Trimming, finger-jointing, gluing, pressing

Ledinek's X-Cut is particularly robust and handles the thick cross-section of KVH with ease. Its feed performance is 190 m/min. Remnants automatically fall into a waste chute leading to a wood residue disposal. Trimmed woods are fed to the finger-jointing line by means of a cross transport. Ledinek supplied Kirnbauer with a Eurozink Compact with a performance of six cycles per minute.

What is special about this system: The processing steps finger-jointing, gluing and pressing are taken care of in one pass. This means that two pieces of wood – in one case its tail and in the other its head – are clamped precisely in position. Then, the milling head with double milling unit goes over them from top to bottom. In that same upward movement, the contact-free glue application is taken care of. Subsequently, the front board is clamped and the back board is pushing onto the front one – creating an endless cycle. Depending on the order specifications, a buck saw will afterwards trim the finger-jointed lamella to the required length.

A major advantage of this technique is the small space requirement. "Furthermore, setting the machine to a new dimension is done in no time," Bernhard Fandl, responsible for sales at Ledinek, confirms. None of the processing steps require any re-clamping. The Eurozink Compact has a fixed guide ruler which precisely aligns the side of the board with zero and makes a positioning of the short end redundant.

Four levels as resting areas

For the curing phase, the finger-jointed lamellas are brought to one of the four levels of H.I.T. During the tour through the new laminated timber plant, Anton is highlighting the careful wood transport:The lamellas are brought to four levels by means of an elevator. In doing so, they are not simply pushed onto a paternoster lift but rather gently hoisted – similar to stacker arms in packaging. The same principle also applies to the relocation of cured lamellas in the further processing process.

Parting ways

Here is where KVH and the lamellas for duo beams are parting ways: KVH goes on to the finished planing unit from Ledinek, a Europlan machine. Lamellas for duo beams, on the other hand, stay on the top floor. First they are put through a Ledinek planing mill (a Europlan as well) to obtain a clean surface. Afterwards, a long H.I.T. cross transport with an integrated turning station takes the goods to the Oest surface gluing.

After truss formation, the glued and loose lamellas are brought to the Lignopress by H.I.T. which is pressing the wood from the top almost offset-free by means of side thrusts and press shoes. "The press force is considerably higher than in comparable systems. This is how we achieve reduced glue use", Anton explains. Just like the KVH, the cured duo beams are passing through the Ledinek Europlan at the lowest level. The maximum cross-sections that the new laminated timber factory can handle are 280 by 600 mm. This is also the dimension that the Europlan planer must take on.

Trimming several pieces at once

KVH as well as duo beams are passing through two conventional patching stations by H.I.T. where one employee deals with two sides of the wood. The cross-cut saw with collet for order picking from H.I.T. can process several pieces at the same time with its 600 mm of width and trims the laminated timber to the desired length. A stacking device makes packages or employees are assembling them by means of a vacuum lifter. Finished packages can subsequently be stretch-wrapped.

Kirnbauer feels well-equipped for the future with the new laminated timber plant. Especially duo beams in both visual and industrial quality – also in larger dimensions – are in high demand due to their form stability and are increasingly replacing KVH.