From the forest to finished product
FML's trained and experienced procurement team select only the most mature trees in the area’s forests and the largest, clearest logs for production into FML fine lumber.
Once the logs are brought in to the FML logyard and are ready for processing, they are loaded onto the debarker. During the debarking process, as the bark is removed, so are the dirt, grit and rocks that may be embedded in the bark, thus providing a much cleaner log going into the headsaw.
From the debarker, the log heads to the incoming log deck that delivers logs to the log turner. The log turner is hydraulically operated and is powerful enough to handle some of the largest White Oak logs that FML buys.
In the headsaw cab, the operator uses hand controls to turn the logs, activate the log scanner and run the 20,000-pound carriage on the headsaw that splits the log into four quarters.
A high-tech scanner provides a 120-degree scan around each log to help the operator determine the best position to make the first saw line in the log. Information such as log count, board footage of logs sawn, and other production statistics are also provided by the log scanner.
Once the log is separated into quarters, it moves to the resaw area. The resaw operation takes over processing the quartered logs. They travel by conveyor to one of two resaws. The resaw slices alternating faces of the quarter log while turning the quarter log end for end on a carousel between each pass through the saw.
Once the boards are cut from the quarter logs, they travel to the computerized optimizing edger to clean the edges of each board for maximum grade yield, then on to the double end trim saw.
After being double-end trimmed, the boards go through FML's newly installed "Exact Modus System" where the thickness, grade, length and width of each board is measured and painted on each board. This allows for more precise width and thickness sorting before kiln drying. This system also tracks each board through the system and archiving that board's history for future reference. Exact Modus also keeps accurate production and yield records. Once measured and marked, the boards travel down the "green chain" where they are stacked in designated bundles before going to the sticking department. Here breeze dry sticks are placed at 12-inch intervals on each layer of boards to allow air movement between layers while maintaining the lumber’s flatness during air and kiln drying.
Once the bundles have sticks placed between the layers, the bundles are placed out in the yard for varying lengths of time according to thickness and species to allow natural air movement to begin the drying process. Thick stock (5/4 through 8/4) is moved to predryers to control the airflow and minimize surface checking. Drying takes approximately 35 days for 4/4, 45 days for 5/4, 3 months for 6/4 and up to 6 months for 8/4, depending on the species.
A wood-waste boiler provides the steam and heat needed for the kilns and pre-dryers. The boiler only burns sawdust produced in the sawing process.
FML is a no-waste facility, so every part of the log is used. Sawdust is separated, is moved by the sawdust conveyor and is stored in the sawdust bin to be used as needed to fuel the boilers for the kilns. Larger wood waste passes through a chipper, a powerful, razor sharp series of eight knives. Chips are sold to paper companies and must be an exact specified size within fifteen thousandths of an inch. Bark removed from the logs in the debarker is sent through a grinder to be made into mulch that is used for landscaping.
The kilns are computer-operated so that each kiln charge is electronically controlled in order to achieve a finished moisture of 6-8% for each species and thickness.
When the lumber has properly dried, the kiln charges go to the de-stacking area where breeze dry sticks are removed from between the layers and the boards are graded, separated by thickness and grade and transported to the warehouse where the bundles are end painted, tallied and stored.
When the shipping department receives orders, the FML team gathers the appropriate bundles and prepares them for shipping. The bundles are banded and labeled (export bundles are triple-banded) and are moved to the staging area in the warehouse for flatbed or container loading.
FML's fine quartersawn lumber has now undergone the transformation from log to lumber and is on its way to other manufacturers for the production of high-end flooring, furniture, cabinetry and architectural millwork all over the world.