An article by Günther Jauk / Holzkurier
Even before taking over the Friesau sawmill, Mercer Timber Products developed an investment plan that the company has consistently implemented over the past five years. With a budget exceeding €70 million, the saw line has been modernized, the log yard upgraded, the entire sorting line rebuilt and expanded with an additional stacking line, waste management improved, and an entirely new planing mill constructed — equipped with a high-performance planer operating at a feed speed of 1,200 m/min.
– We needed to make up for postponed investments while also increasing capacity and improving the production flow. It was important to us not only to focus on volume, but also to strengthen value-added processing in order to increase profitability, says CEO Dr. Carsten Merforth.
Today, the annual cutting volume stands at 1.4 million m³ of timber. In addition to the domestic market in Germany, where Mercer primarily supplies raw material, the USA, the UK and Japan are important export markets.
A well-thought-out system
To ensure optimal supply to the new high-performance planing mill, Mercer invested in increased drying capacity – and chose the Swedish continuous kiln specialist Valutec.
– We deliberately chose continuous kilns because they enable us to achieve up to 50% higher output relative to the same floor area, explains Merforth. He also highlights the high drying quality and flexibility as key decision factors.
The company ordered two TC continuous kilns, each with ten zones. The TC principle is based on serially connected, individually controlled drying zones, each with its own air and heat supply. The lumber packages move lengthwise through the kiln, while the air flows transversely – at a 90° angle to the feed direction. This setup allows different lumber dimensions to be dried simultaneously, with total drying time determined by the thickest dimension.
“We deliberately chose continuous kilns because they enable us to achieve up to 50% higher output relative to the same floor area.”
— Dr. Carsten Merforth, CEO, Mercer Timber Products
Promises exceeded
When it comes to performance and quality data, Valutec is known for being conservative in its commitments.
– We only promise our customers what we know we can deliver 100%. That’s why it often happens that our installations perform even better than guaranteed, explains Eric Johansson, Marketing Manager at Valutec.
This was exactly the case at Mercer.
– The drying quality guaranteed by Valutec has not only been met but even exceeded – including when drying beetle-damaged spruce with highly varying initial moisture levels, says Jan Kiesewetter, Head of Technical Projects at Mercer Timber Products.
Merforth adds:
– Thanks to these excellent drying results, the quality of our planed products has also improved significantly.
The same goes for capacity. Valutec’s stated annual output of 125,000 m³ per kiln has been greatly surpassed – Mercer now achieves over 300,000 m³ per year in total.
Kiesewetter also points out additional benefits of the continuous kilns, including simplified logistics and improved workplace safety:
– We now have significantly less forklift traffic, and the kilns are much easier to operate since sensor insertion is no longer required. We also no longer need to use concrete weights on the lumber stacks, as these are now supported by pressure frames inside the kilns.
Together, the two TC kilns at Mercer Timber Products dry more than 300,000 m³ of sawn timber per year.
Precise planning through simulation
To further optimize the drying process, Valutec developed the simulation software Valusim. It allows users to simulate the optimal drying process — whether the goal is to minimize energy consumption, maximize quality, or increase capacity.
The software also makes it possible to design the most time-efficient drying schedule for new dimensions, avoiding costly trial runs.
– We use Valusim when introducing new dimensions and when drying mixed cross-sections. It allows for much more precise planning, explains Kiesewetter.
A third kiln on the way
Merforth and Kiesewetter are equally pleased with the smooth installation and commissioning process:
– Valutec followed the timeline down to the day, and we were able to start production without any rejects from day one.
Part of this success is also due to Scantec, Valutec’s representative in the German-speaking region, responsible for sales, project management and after-sales service.
Valutec has successfully collaborated with Scantec for many years, and the Swedish company highlights the importance of Scantec’s strong local presence as part of its customer service model, Johansson emphasizes.
Already in spring 2023, Mercer will receive another TC continuous kiln from Valutec — with ten zones and an annual capacity of 156,000 m³ of sawn timber.
A better testament to customer satisfaction is hard to imagine.
