Tolko Plans High Prairie Rebuild

Tolko Plans High Prairie Rebuild

Tolko Plans High Prairie Rebuild

Tolko Industries Ltd. has commissioned Dieffenbacher to supply the core components of a new OSB line at High Prairie, Alberta, Can. On May 20, 2022, a fire in the press building damaged beyond repair a Dieffenbacher 12-opening press, which Tolko had commissioned in 1995, and much of the surrounding equipment. A Dieffenbacher CPS+ continuous press will replace the previous press.

Dieffenbacher’s scope of supply for the rebuild of also includes the forming station and forming line, and the raw board handling system. In line with Dieffenbacher’s CEBRO smart plant concept, the Press Emission Control System and the Intelligent Air Management System will improve the plant’s sustainability by creating cleaner air inside and outside the production hall. Dieffenbacher’s new digitalization solution, EVORIS, and the digital service platform, MyDIEFFENBACHER, will help make Tolko’s new plant a truly “smart one.”

“It’s great that Dieffenbacher stepped up so quickly to help us after the fire,” says Fred Chinn, Vice President Strand-Based Business at Tolko. “Once we rebuild, High Prairie will be better than ever, and our new CEBRO smart plant will be a big part of that.”

High Prairie OSB mill readies for upgrade.

Chinn believes the plant will produce its first new board by year’s end. Once operational, the plant’s annual production capacity will reach up to 734,000 m³.

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March 2023

March 2023

March 2023

Cover: QC Special Section

Quality Control, need we say more? A dozen suppliers weigh in with their latest QC technologies and systems.

Inside This Issue

COVER: Quality Control Special Section

EDITOR’S NOTE: The following companies submitted editorial profiles to complement their advertisements placed in Panel World March 2023.

  • Argos Solutions
  • Baumer
  • Biele Group
  • CMC Texpan
  • Custom Engineering
  • Fagus GreCon
  • Imal-Pal Group
  • LIMAB
  • Raute
  • Siempelkamp
  • Taihei Machinery
  • USNR
LeBlanc Has Settled In As Leader Of Longtime Closely Held Hunt Forest Products

EDITOR’S NOTE: Since this is the March issue of Panel World, and March means baseball (to some people), what better person to interview than Richie LeBlanc, president and CEO of Louisiana-based Hunt Forest Products, LLC? No, we’re not interviewing him about baseball because his insights into the forest products industry take center stage here.

Emphasis On Customer Support Bodes Well For Dieffenbacher U.S. Operations Moving Forward

EDITOR’S NOTE: Dieffenbacher Customer Support, LLC has completed 10 years of operation in the U.S., and with that in mind Panel World tossed several questions at Bernd Deffland, President & CFO; Colin Folco, Director Modernization; and Rolf Krey, Director After Sales.

PROJECTS
  • Tolko Plans High Prairie Rebuild
  • RoyOMartin Plans More Work At Chopin
  • Southern Veneer Upgrades Pendulum
  • Wisewoods Orders Refining System
  • Steves & Sons Orders Door Skin Lines
SUPPLY LINES
  • Con-Vey Promotes Goebel To VP
  • Buttner Expands Product Range
  • Dieffenbacher Buys Energy Firm
  • Peak North America Acquires Endurance Equip
  • Daubert Names New Leadership
CLIPPINGS
  • Pacific Woodtech Rebrands As PWT
  • Egger-Lexington Enhances Recycling

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Taking Stock: Heck Of A Commercial Dispute

The temporary closure of Structurlam’s Conway, Ark. cross-laminated timber (CLT) and glulam plant and the apparent severing of the plant’s relationship as a major supplier for Walmart’s new low carbon footprint and energy efficient corporate campus in nearby Bentonville marks yet another growing pain for an industry that’s just getting started realizing its amazing potential.

In 2019 Structurlam announced that the new campus project was to be fed by Structurlam’s new CLT facility that included a $90 million investment to upgrade a former steel mill and convert it to a CLT plant. Structurlam would become the “exclusive supplier of mass timber products” to the new Walmart home office campus, covering 350 acres, two million square feet of floor space and multiple office buildings.

The project moved along, and many were surprised in January this year when Structurlam officials announced the plant would be closing due to a customer contract cancellation, and we can only assume it means Walmart, though Structurlam refers now only to the “customer,” and says there are no plans to enter into a new commercial agreement. Walmart has announced it is still committed to its new HQ project and would be looking at other suppliers.

As to what happened, Structurlam CEO Matthew Karmel refers to it as a “commercial dispute, but we cannot discuss the specifics.” More specifically, according to sources in the CLT industry, the plant may have “overcommitted” to Walmart while dealing with startup issues, and there may have been dispute over product quality or composition. Then again, Structurlam started up and began delivering product in the teeth of the pandemic, experiencing supply chain issues and lumber price increases that weren’t planned for.

Following the 2021 bankruptcy of Katerra and its CLT plant in Spokane, Wash.—which set out to revolutionize the construction industry using pre-fab building and mass timber construction principles but couldn’t get out of its own way—the mass timber industry had re-gained the momentum, and is definitely expanding as designers, engineers and architects learn more about it. A couple of recent developments:

  • Officials with Freres Lumber in Lyons, Ore. report their mass plywood plant is booked out several months of production and is supplying a large 18- story mass timber office building project in California, working with a major commercial builder that recently started a new mass timber building division.
  • CLT producer Smartlam in Dothan, Ala. recently announced an expansion to add a new glulam beam line.

Back to Structurlam, CEO Karmel says the state-of-the-art Conway plant has met the vigorous startup challenges “with flying colors—its cross-laminated timber and glulam production capabilities already exceed its plan objectives and its processes have been validated repeatedly by the APA to exceed U.S. regulatory standards.” And, Karmel adds, Structurlam is in a strong position to resume Conway operations as the rapid growth of mass timber across North America continues to drive demand for manufacturing capacity.

That is, with Walmart out of the way, the Conway facility now has the ability to support new customers with more than 1 million cubic feet annually of mass timber products.

Article by Dan Shell, Senior Editor, Panel World

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Carroll Is COO At Swiss Krono

Carroll Is COO At Swiss Krono

Swiss Krono Group appointed Steve Carroll as its COO and Technical Director for U.S. operations at Barnwell, SC.

Carroll comes to Swiss Krono from Arauco North America where he most recently served as director of the Grayling, Mich. operations. He brings to Swiss Krono more than 30 years of experience in the wood industry.

“Steve’s strong performance in the building products market segment, specifically his previous work within the U.S. wood manufacturing industry, makes him the ideal person to oversee our operations. We look forward to working with Steve as Swiss Krono continues to grow its presence in the United States,” says Erik Christensen, CEO of Swiss Krono USA.

Carroll joins the Swiss Krono USA management team composed of Christensen, Aaron Johnson (finance) and Kyle Brown (sales & marketing).

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CPA, APA Leaders Size Up Situation

CPA, APA Leaders Size Up Situation

Leadership from two of the major primary panel production associations provided 2022 year-end reports, while also looking ahead to 2023 and both pointed to economic issues moving forward.

“This year (2022) was more ‘back to normal,’ as the COVID pandemic was mostly in the rearview mirror. There were still a few ‘hangovers,’ with the supply chain still being constrained and a shortage of workers limiting productivity,” commented Andy O’Hare, president of Composite Panel Assn. (CPA).

O’Hare added, “The new boogieman is sticky inflation and its cousin high interest rates. We saw the effects of the latter two elements in the fourth quarter of 2022, with declines in composite wood panel shipments. The commercial and residential housing markets have been significantly impacted by the increased interest rates, which will negatively impact construction activity into at least the first half of 2023. We can be hopeful that inflation will wane progressively over the year and be back in the 3-3.5% range by Q4 2023, with an accompanying reduction in interest rates.”

Formaldehyde and climate change policy developments dominated in 2022, O’Hare said, with most of the formaldehyde action occurring in Canada. Health Canada finalized its Formaldehyde Emissions from Composite Wood Products regulations in 2021 and CPA worked with the ministry throughout 2022 to clarify several details in anticipation of the rule going into force in January 2023.

In the U.S., EPA rolled out an updated version of the Integrated Risk Information System (IRIS) for formaldehyde, a hazard and exposure assessment for the chemical, which will inform the risk assessment under the Toxic Substances Control Act (TSCA). The IRIS assessment is presently under review by the National Academy of Sciences.

Meanwhile, the U.S. Congress passed a climate change bill in August, titled “The Inflation Reduction Act,” which is heavily focused on promoting carbon free electricity generation and incentives for electric vehicles. There are also provisions encouraging the federal government to procure “low carbon” building materials, which could enhance consumption of products made with composite panels. Potential benefits for CPA members will be clearer in 2023 when these programs are implemented.

With climate change being a focus of the national and international policy dialogue, Gary Heroux, CPA technical director, initiated a study late 2022 to complete the environmental lifecycle work begun several years ago. This work in 2023 will examine the “plant gate to grave” portion of the composite panel lifecycle. This will allow CPA to account for the fate of the carbon stored in composite panels after the products in which they are contained have reached the end of their life.

Mark Tibbetts, President of APA—The Engineered Wood Assn., described 2022 as a year of transitions. “Thankfully, we put much of the disruption of the pandemic behind us. We held our first Annual Meeting since 2019. We also returned to routine mill audits and in-person meetings within our Technical Services and Field Services divisions.”

One lingering impact, Tibbetts noted, is inflation—with the response of tightening monetary policy being felt most acutely in the housing market. On a year-over-year basis, new housing starts dropped 16.4% since November 2021, with single-family construction declining 32.1% over the past 12 months.

“I believe we are in store for a shallow recession and don’t buy into the Fed taking its foot off the break,” Tibbetts said.

Tibbetts noted several positives. APA’s proposal to allow OSB sheathing in floor construction in high-velocity hurricane zones in Florida, mainly Miami-Dade/Broward counties, was recommended to the Florida Building Commission for approval as part of the 2023 Florida Building Code by the Florida Code Committee.

APA’s Quality Services Div. spent much of the year conducting a comprehensive review of APA’s quality program and APA is aligning processes across regions, improving documentation and quality of the work product.

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Tribal Focus On Several Acres Of Public Wetlands Dooms Huber OSB Project In Minnesota

Tribal Focus On Several Acres Of Public Wetlands Dooms Huber OSB Project In Minnesota

Tribal Focus On Several Acres Of Public Wetlands Dooms Huber OSB Project In Minnesota

“Once again, the state of Minnesota is giving the finger to good companies trying to create jobs here. Huber has been a phenomenal community partner everywhere they have operated, with a sterling environmental record. Huber was bringing hope to a community that needed some good news. It is disappointing the Leech Lake Band—and now the court of appeals—would stand in the way of that.”

That’s how Minnesota State Senator Justin Eichorn (R-Grand Rapids) responded to a Minnesota Court of Appeals decision in early February that would have caused further delay in the construction of a $440 million OSB plant by Huber Engineered Woods in Cohasset, but instead immediately prompted Huber to pull out of the project and begin looking to another state for the development of its sixth OSB plant.

HEW President Brian Carlson states, “Due to delays that jeopardize our ability to meet product demand deadlines, we will pursue development of our sixth mill in another state.” Carlson says the company appreciates the strong support provided by a range of Minnesota constituents, including “state, county, city and local officials, government and private sector community development groups, and the residents of Itasca County, and that the Huber team looks forward to maintaining a constructive relationship in the state.”

HEW announced in June 2021 its plan to build the plant on nearly 200 acres adjacent Minnesota Power’s Boswell Energy Center and create 150 direct jobs with additional job and growth opportunities for area logging and trucking operations.

Huber OSB packaging line in Spring City, Tenn.

But in a ruling on an appeal from the Leech Lake Band of Ojibwe (its reservation is a mile west of the proposed plant) and the Minnesota Center for Environmental Advocacy, the court of appeals said the Cohasset city planners’ earlier decision to only require an Environmental Assessment Worksheet (EAW) of the project, and not require a more detailed Environmental Impact Statement (EIS) needed to be re-addressed by the city because of issues involving a few acres of two “public waters wetlands” that state law would require an EIS for.

The state of Minnesota requires a “responsible governmental unit,” such as a city planning body, to determine if a project requires an EAW or EIS, or both.

The appeal from Leech Lake Band of Ojibwe and Minnesota Center for Environmental Advocacy also asked the court to weigh the environmental effects potentially caused by air emissions from the new OSB plant and from the volume of timber harvesting that the plant would require. The city had determined there would be no significant environmental effects from either, given the permitting and planning requirements the project would require going in. The appeals court ruled in favor of the city as to “no significant environmental effects” and against the Band and the Minnesota environmental group.

But the court took to task the city’s determination that an EAW was enough for the project with regard to public wetlands. Huber initially submitted an EAW and then, at the city’s request—following additional consultation and review from local citizens, state agencies, and other interested parties, and providing more information about the health of Minnesota’s forests and their ability to sustainably supply the facility, and providing more detail on the project’s carbon footprint, especially regarding the effects of generating much of the facility’s energy needs through wood fuels, and the carbon sequestration effects of the finished wood products—re-submitted the EAW, which the city accepted while deciding an EIS wasn’t necessary.

The Leech Lake Band of Ojibwe appealed, and the appeals court agreed, that the facility “falls into categories” for which an EIS is mandatory under Minnesota law, specifically as to the elimination of public waters wetland.

The city had determined that the project would not eliminate public water wetlands. But the court focused on two small public waters wetlands, which the court said are “accorded greater protection under state law” and should require an EIS beyond an EAW.

The court noted that the state’s definition of public waters wetlands is 10 or more acres in size in unincorporated areas and at least two and a half or more acres in incorporated areas. Huber’s EAW explained that its project would involve filling portions of two public waters wetlands, both in incorporated areas: 8.73 of 14.27 acres in one and 1.65 of 5.67 in another, and that while there would be a reduction in the size of each, it wouldn’t “eliminate” the public waters in question and only reduce the size, and thus not require an EIS. The city agreed that the partially filled public water wetlands would not fall below the 2.5 acre threshold after the partial filling.

The appeals court, however, said the state law did not explain what it means to “eliminate” a public waters wetland, and took the liberty to base its ruling that “eliminate” can also mean to “modify” the public waters wetlands, and ruled that because the project would alter the characteristics of the public wetlands the city should apply this legal standard and re-assess whether an EIS is necessary.

The Leech Lake Band also said the public waters wetlands fillings would have significant environmental effects that should require an EIS and that the city failed to consider these. The Band said the wetlands Huber planned to fill are a filter for water quality that nearby wild-rice beds depend upon, and removing the wetland filters would be harmful to the water quality that the rice requires. The court agreed, noting the city did not investigate or explain how wetlands replacement (as the project would entail) or stormwater controls would protect the wild-rice bed and other resources downstream.

The court said the city should reconsider given these stipulations and then issue a revised decision on the need for an EIS. Huber’s withdrawal from the project apparently now renders such an exercise as unnecessary.

“The court decision issued today is a major victory for the Leech Lake Band of Ojibwe and serves as a powerful reminder of the importance of respecting the sovereignty and treaty rights of indigenous nations,” comments Band Chairman Faron Jackson, Sr. “The proposed OSB mill project posed a clear threat to our sacred resources, including wild rice and wildlife, while bypassing an important step in the environmental review process.”

Upon the announcement of Huber’s departure, Tamara Lowney, president of Itasca Economic Development Corp., told the Duluth News Tribune, “Today really feels like a funeral in my office, saying goodbye to the biggest opportunity that our region and our northern part of the state has seen in decades.”

The project would have replaced lost jobs and tax base as the adjacent Boswell coal-fired energy plant shuts down its coal burning units and possibly reconfigures to renewable energy sources.

The Cohasset OSB mill would have been Huber’s sixth, following facilities in Maine, Georgia, Virginia, Tennessee and Oklahoma. Had the timeline not been delayed from the outset, Huber’s construction of the plant would have occurred during the current OSB market softening, possibly putting it in prime position upon startup to take advantage of the next market strengthening.

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