How to start cutting wood?
Before giving practical advice on opening a sawmill, I would like to consider the purpose of this undertaking in terms of marketing. If you intend to turn on the production of such products to meet all the needs of customers, this targeted approach is not as simple as it might seem at first glance.
And there is a marketing movement that is totally opposite to the first one. His direction would be to sell the goods already produced.
BASIC DIFFERENCES
It depends on the choice of target, the selection of personnel, the choice of equipment, and the further promotion of your business. Naturally, the first approach implying a direction towards the end user has a better chance of success. This long ago, in the 60s, he realized that western manufacturers were replacing the mass production of monotonous products for mass production. Thus, in Europe, the Wood-Mizer plant, which specializes in assembly of machine tools, uses the first marketing approach - the functionality of each device depends on the customer's wishes.
Thus, focusing on the consumer should ensure that your company's equipment selection, functionality, ease of maintenance, reliability, and easy restructuring for the release of another type of product.
However, if you still continue for the second year, ie if you focus on marketing already finished products, you should spend more time with staff, focusing on selling the goods in any way. In this case, you must master the art of persuasion and be able to change the price.
HOW DOES EVERYTHING START?
How is the idea of creating a sawmill? There are basically two different options.
First choice
A ready-to-use wood processing company with full capacity, a solid customer base and an established sales process conducts economic analysis at a time and concludes that if the board is used on its own, it will be more profitable. Thus, a decision is made to open a sawmill.
Of course, instead of starting from scratch, it is much easier to develop a sawmill business on the basis of a ready-made business with a pre-established customer and well-established sales. And yet, when you start to open it, you have to weigh everything again, analyze it carefully and calculate it. It would be good to insure the sawmill for the first time, preparing a stock of processed raw materials, so that the workers gained time to meet the equipment and master the production process.
Second option
And the second, more complex variant, is to dominate a completely new field of activity. It is often the beginning of entrepreneurs with roundwood in their hands and they decide to make money. Sawmill is the main element of woodworking. This means that even if you want to make furniture or log houses, the whole process should start with saws, and panels, like the end product, must cover your equipment costs for a certain period of time. This will give you an opportunity to develop your business in the future.
TECHNOLOGICAL PROCESS
We warn that all calculations given in this article are approximate and only show a general vision of project development. You must make your own decision, taking into account the prices in your area.
Well, we want to open a profitable sawmill by investing $ 100,000 in the initial phase. Although both are not perfect, we choose tape and circular technology to cut wood. For example, the band saw gives a small productivity and round cuts of finished timber - increased energy consumption and a larger cutting thickness, which increases the loss of raw materials. But if they work together, to some extent this will compensate for their shortcomings and protect their dignity.
Horizontal banding machines should be preferred to cut logs because they can handle large saws with a thickness of 1000 mm, while competitors with circular saws cannot afford it. The use of such machines reduces the consumption of raw materials because the band saw has a cutting thickness of up to 2 mm, while the thickness of a circular saw is 6-8 mm.
After the band saw is cut, we receive uncut sheets that are fed to the circular saw for further processing. Because the thickness of such a sheet is less than several times the width, a thick cutter of the circular saw does not reduce the volume yield of the sawn timber.
The average diameter of the forest and the way it is cut greatly affect the productivity of the site. When using the scaffold ta maintenance-free test saw scheme, the edge trimmer will be loaded the most and the efficiency of the entire site will depend on it.
When sawing with "Brusovka" is used, you must focus on the features of the band saw machines or focus on saving with the edge trimmer. In general, the efficiency of the area will depend largely on post-harvest mechanization.
Sawlog average thickness - 40 cm;
Sawn timber cross section - 25 x 150 mm, 50 x 150 mm;
Sawlogs (and panels) are 6 m in length;
Feeding speed:
tape machine - 12 m / min;
edge trimmer - 30 m / min.
Operating mode in two shifts for 10 hours; Within one month - 22 working days. day.
WORKING PROCESS
Loading round billets on band saw. The equipment used is a mechanism for the individual transport of saw materials; driver. The coefficient which considers time loss is 0.9.
Preparation of saw logs for sawing: conical compensation; clamp. On average, it takes 1 minute per day.
Sawing of logs. The operation begins with the workers initially producing 8 cutting and 8 turns of the cutting head. The worker must rotate the saw three times and ensure the taper once again. The result is 4 pieces of wood, each 25 mm thick. They are then fed to the edge trimmer for processing. The whole process takes 8 minutes.
This bar will be cut into eight clean-edged boards, measuring 50 x 150 in just four cuts. Thus, the process in which workers make four interruptions and return the car and intermittently remove and place the panels takes approximately 3.5 minutes.
And this means that the process for cutting a log with a diameter of 40 cm takes about 12.5 minutes from the workers, using a very simple cutting scheme. According to GOST 2708-75, the volume of these billets is 0.9 cubic meters.
During operation, every two hours or, if necessary, the sharpener cutter must replace the belt machine. For the exchange, approximately five players will spend about 30 minutes of the total time.
The human factor should also be taken into account. The workers will naturally get tired, so we have to accept that productivity will fall, or we will have to introduce technological breaks. A ten minute break is recommended every 50 minutes. Then the time loss per shift will be 1 hour and 40 minutes.
PRODUCTIVITY
What can we draw from them?
On a ten-hour shift, I saw a band that saw about 30 cubic meters of sawing from three people. This means that a beneficial output of cut goods will be about 50%. Result: A band saw will produce 15 cubic meters of timber for 10 hours.
If we install two band saws on our site, we will realize the total capacity of the workshop in one month - 1320 cubic meters of finished product.
WHERE TO WASTE?
After all processing for the production of finished timber, we still have a large number of scrap and sheets. We can use it as a flammable material for boiler rooms working on firewood, or we can get some smaller timber from them.
Once the initiative is developing, it is better not to process the plate to reduce equipment investment. However, once the sawmill has reached its designed capacity, it is possible to buy the miter cutter and gobblerlezny machine and make the processing process high-quality timber.
CUTTING ROUND BILLS: A CUTTING MAP, A REQUIRED VEHICLE
Woodcutting is an operating cycle using various technologies aimed at obtaining round timber suitable for further use in industry: The duration of the process and labor costs depend on the chosen round wood processing method as well as the time of year.
VEHICLES AND EQUIPMENT
In production there is a trunk and a large branch size. All material is divided into groups with the presence of thickness and shell. Generally, forestry enterprises have workshops near the harvesting site where the first woodworking machines were installed.
Manual peeling of forest
The wood that has not undergone the drilling step can be used as a tread beam in a flooring device or in a suitable interior, or as a supporting device during construction.
Industrial peeling of forest
If another version of the use of the tree is planned, then the cut is performed and the output has the following sections:
Uncut and semi-cut (rough material on which the floor, wall or ceiling floors are mounted);
edged (designed for finishing).
A sawing organization can implement a saw with all the necessary tools.
Map of a tree saw
The rational use of the material is achieved by pairing with the saw map. This allows you to reduce production costs with waste that can significantly reduce the amount of waste. The types of vehicles and forestry equipment used depend on the volume, desired quality and size of the finished timber.
Wood cutting machine
Most often it uses a circular saw and several machines:
Due to the circular saw, it allows circular, precise cuts in different directions. Perfectly handles the diameter of the round log above average, suitable for both professional and home use;
saw;
Machines for clean removal of the shell;
On a band saw machine, the saw is considered the most popular because it allows the processing of dense logs, yielding good quality materials and a small amount of waste;
disc machine: production of double-sided beams and uncut sheets;
Frame sawmill does not need a foundation, with the use of technology allows you to install equipment in the immediate vicinity of the cutting area;
millimeter, processes universal machines, produces high-quality building materials even from low-grade whips;
The sawing of round wood in a large woodworking enterprise should be done with the largest quantity of timber that differs from others in specific quality and precise dimensions. For this purpose, special cutting lines are installed.
In the sawmill, the beam and the edge slab are obtained by means of a log cut 7 m long and 15-80 cm in diameter along the longitudinal line. The circular saw has one or more discs, processing a different diameter of the forest according to their number.
If you are going to process a small amount of wood at home, you can use a normal saw.
WOOD SAW
Before selecting a tool, you must determine the type of cut by focusing on the annual rings of the log. There are several kinds:
radial (radial);
tangential (with a radius parallel, touching the annual rings);
The fibers were placed parallel to the cut.
Among the cutting methods, selects the most appropriate for a particular situation:
It's invasive. Wood cutting in this way is made to deciduous trees with a small barrel thickness, is considered the simplest treatment. Yield: uncut and curved.
If there is another woodworking machine, it is possible to cut up to 65% of the material for the output of the same edged boards. First, double-edged beams and sheets are cut from the sides and then some edged lumber is produced.
More specific methods are sector and segment sawing. The number of elements in the first method ranges from 4 to 8 and depends on the thickness of the body. After separation, elements from each sector are impaled along a tangential or radial line. The second method begins with the beam exiting the central portion and the plates are removed from the lateral portions along the tangential direction.
A circular method is suitable for cutting a tree individually. It resists turning the slab 90 ° along a longitudinal line after each cutting board. This allows you to monitor wood quality and remove affected parts of the body in a timely manner.
HANDMADE: USE CHAINSWS
For domestic barrels of several barrels, the purchase of a product is not feasible, the cost being several times higher than the price of finished products. If you have the necessary skills, it is more efficient and less expensive to do all the necessary work with a normal saw or chain-powered equipment. Of course, such studies require much more physical expense and time, but the price of the substance is significantly reduced.
Working in the garden requires pruning fruit trees and at the same time, it becomes possible to produce additional material for home buildings without resorting to the services of experts, so that any enthusiastic owner would prefer to buy a saw. Often, the coniferous species are harvested for the home with a cut that is perfectly processed with this tool. Smooth bodies make cutting speed easier and increase the speed of work. Professionals, meanwhile, often use a chainsaw because it is more powerful than electricity and can be used anywhere, regardless of the power supply being cut or disconnected.
Options for cutting wood
A tool such as saw attachment, guide saws and base stud fasteners will be required for the chain saw to work on cutting logs. The paper clip in the form of a frame is connected to the tool so that the distance between the chain and the frame can be adjusted. This is done for the output of the timber of finished timber of different thickness. The role of the guide can take the desired length profile or a flat wooden rod of sufficient rigidity. Designed to cut the body, a special chain was selected for the vehicle. The difference is that the teeth are sharpened at an angle.
Before you start working, you don't just have to prepare all the necessary tools. Regardless of whether a woodworking machine or manual fixture is designed to cut a trunk, the first step is to become familiar with the saw map. This is done to minimize the percentage of waste and increase the yield of useful products.
The first thing you should worry about in longitudinal cuts is the uniform density of finished sheets. For this purpose, an authorized saw blade guides the tool to the west side of the log or the opposite direction. This is because the round wood in the northern part depends on the density in the south.
The chain saw is then removed from both sides to obtain a double-sided rod. In contrast, it is cut in accordance with the selected cutting scheme at the beginning of the job. The outlet is an uncut board. If there is a certain amount of defect in the trunk, a circular cut can be made by turning the body to the right or 180 °.
QUANTITY OF FINISHED MATERIAL, CUT PRICE
The yield of useful materials obtained from conifers and hardwoods is different in percent. For lumber from coniferous trees, the following indicators are characteristic:
The percentage of finished timber will be the highest (80-85%) provided that the process is performed by a professional and a disk saw mill is used;
The edged material produced by the machines is 55-70% on average;
When working with a saw, it increases up to 30% of uncut wood waste.
Figures are given regardless of the amount of finished timber up to 30%. However, such materials go to products that allow a certain marriage.
Finished wood products after sawing
Hardwood roundwood yields 60% of unfinished cut timber and about 40% of edge. This is explained by the initial curvature of the round tree. You can increase the number of products received: This will require a variety of forestry machines. A certain type of device can increase the amount of timber by 10-20%. A timber will need about 10 cubic deciduous roundwood. Additional equipment installation price will pay for the price of the finished forest. Special lines give a larger volume, but their use is recommended only in a wide area. In an ordinary sawmill, the average price of sawwood will be about 150-180 rubles per cubic meter of sheet.
MAP SAW
The saw map is the calculation of the optimum amount of finished timber from a log. It can be calculated independently for each concrete diameter of a slab, or you can use a computer program that makes the calculation considerably easier and is very affordable.
Material output after tree cutting
Or the welding can be a normal guide for the saw mill job. The result is a base table. The sawmill should always be data-driven to obtain more timber from any tree.
RATIONAL CUT OF ROUND WOOD: TABLES, MAPS, TABLES
The economic efficiency of sawmill production depends largely on the degree of use of raw materials. The equipment used in production determines rational cutting logs for optimal materials, competent planning in cutting, efficient use of resources and therefore high quality products.
BASIC PLANS OF CUTTING SAWS
The methods and diagrams of cutting logs depend directly on the requirements for the quality and size of the products, the characteristics of the raw materials and the type of equipment used.
Main ways to truncate logs
but - phoned; b - with brusovka; b '- by taking the two bars; b "- in sectors," in sectors, "- cutting sector in radial panels" - in tangential panels; r - segment; r '- razvalno-segment; d - circular, 1 - solid boards, 2 - edged boards, 3 - shelves, 4 beams, 5 - sections, sectors in the form, 6 - sections in logs, 7 - unilateral boards
Open logs include splitting along parallel planes with one or several cutting tools. This scheme allows you to obtain sheets that have different layers of layers and are not cut according to annual layers. The method is rational for cutting logs up to 18 cm in diameter and is used for saw logs with curved bodies (mostly used for cutting birch raw materials with a simple or complex curvature of 70%).
Uncut boards are obtained after cutting, machined to the edges or billeted in uncut form.
If the amount of finished products available has specified cross-sectional dimensions, the cutting method is applied. with brushes. This scheme is also used to cut large diameter billets in general purpose sawn timber production.
With Brusovka, sawing is performed on two-sawing equipment with two saws. At the same time, in the first stage of the round wood takes the thick measuring rods as necessary sheet. These beams are then divided into sheets of desired size.
It is used to cut large-scale logs segment and sector methods. It should be noted that these schemes are specific and are used in special construction types for the production of tangeneral and radial saw lumber.
Individual cutting of large billets and billets by internal decay is carried out. round
Round wood processing by milling
The cutting of the sawlog raw material by grinding is accomplished by combining this method with the saw. Three main cutting schemes are used:
obtaining a double-beam beam in the first node;
receiving uncut sheets and double-sided beams in the header machine;
Production of slabs on an equipment and production of profile beams in dimensions corresponding to the dimensions of the edged timber cross-section.
The double-sided beam is a semi-finished product for further production of edged lumber by dividing the lumber into sheets.
The main methods of cutting logs with milling
a - obtaining a double-sided beam in the head machine; b - obtaining double-sided beams and uncut sheets; To obtain a profile beam; d - to obtain sawn timber with long edges; d - production of edged lumber of various lengths; e - Production of sawn timber with edges of different lengths and widths; 1 - Cut timber area; 2 - edged timber; 3 - shaped bar; 4 - double-edged beams; 5-edged timber
THE CONCEPT OF PUTTING ON A CIRCULAR WOOD
The supplier is a set of saw, clamp and interconnect plates set up in the saw frame to produce saw mills with specified thickness parameters.
In other words, the supply is a plan scheme for the homogeneous cutting of saw logs (billets) of quality and size for the products of the specified parameters and quality.
When the saw is cut, the delivered delivery is made with a digital series that shows the thickness of the saw boards in millimeters:
These figures show that two 32 mm thick sheets were cut from the middle portion of the slab and four 19 mm thick sheets were cut from the side parts.
For example, in the event of a fault with brusovka, the records are recorded in two rows for logs (first pass) and beams (second pass):
19-19-150-19-19 (first pass);
19-32-40-40-32-19 (second pass).
As in the previous example, these figures are produced in the head machine of the first row in which the slab is cut, a bar of 150 mm thickness and accordingly 19 mm (two on each side), and four non-planks in the second machine A set of timber, 40, 32 and 19 mm thick plates.
When cutting logs on single-saw machines, the setting determines the cutting order.
PREPARATION OF ITEMS
Delivery essentially means determining the optimal dimensions and proportions of the plates in terms of thickness, which allows rational use of the cross section of the plate diameter.
Basic rules of delivery:
Messages must be symmetrical;
In a supply, there should be no different plates less than 5 mm thick;
Compiling the start of delivery with the largest sawn timber in the section;
The dimensions of the thickness of the plates should fall from the axis of the log to the periphery;
when sawing the raw materials in saw mills, the saw edge of the saw is not provided more than two thin (16, 19 mm) sheets;
The height of the beam at the first pass is selected according to the width of the leader plates in the specification for the thickness of the plates;
in the second pass, the planks of the drawn beam are cut into sheets of equal thickness;
When compiling timber supply without a specification specification, use table or graphic methods;
When cutting with the Brusovka method, the thickness of the beam is determined from the ratio of the corner diameter of the log-d (0.06-0.08);
The installation should not exceed the maximum log diameter coverage;
The smallest thicknesses of the central plates are:
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