If you want to cut more, always receive high-quality lumber, pay less for each cubic meter cut, and not have problems with employees - purchase a modern, productive band sawmill.
It should be noted right away that a simple sawmill cannot be productive and efficient without technological equipment. When planning to purchase a sawmill, decide how much you need to cut daily (monthly, annually) and what your profit will be (income minus costs). Then determine the payback period - as the ratio of profit to the cost of purchasing a sawmill. Compare payback periods for sawmills different prices and productivity. How shorter period payback, the more effective your business will be.
Due to the prevailing approaches and conditions for the development of the sawmill business, the predominant number band saws oram - inexpensive sawmills in a floor-mounted design. Their only advantage is the price.
The main disadvantages of such sawmills:
Low productivity;
Low quality lumber;
Difficult working conditions.
The productivity (output) of such sawmills is low, averaging 4-6 cubic meters of saw logs per shift. Such production of a sawmill does not make it possible to pay the worker a decent wage, and the owner to make a profit.
Therefore, a business on floor sawmills is most often justified as a family business, without hired workers, when all income remains in the family.
The work on such machines is frankly hard, not prestigious, and not everyone has the strength or desire. Therefore, it is surprising when wealthy companies choose floor sawmills, knowingly dooming themselves to low efficiency and eternal problems with personnel.
Productive band sawmill:
1) provides high sawing speed;
2) ensures high quality lumber;
3) easy to manage;
4) ergonomic, making the worker’s work as easy as possible;
5) has the ability to be built into a sawing production line;
6) has a long service life.
A productive band sawmill must have:
1) the maximum possible power of the main engine corresponding to the band saws used;
2) automatic feeding, which does not require operator participation directly in the sawing process, while at the same time ensuring high quality cutting;
3) automatic installation of the saw to the thickness of the board, quickly and accurately;
4) log tilter, fast-acting and not requiring highly qualified operator;
5) a desktop raised above the floor to a height close to ergonomic;
6) devices for quick clamping of logs and beams;
7) devices for quick and easy unloading of timber and boards;
8) bark cleaner (debarker).
The above list is implemented in the sawmills of the ASTRA S company.
Production model PLP-ASTRA-EC meets these requirements, which practically allows sawing per shift up to 15...18 m3 lumber onto the board, provided proper organization labor and wages at the sawing site.
The main time is spent on the implementation of the cycle:
lowering the saw unit to the thickness of the board to be sawn – bringing the saw to the log – soft plunge – sawing at the highest possible speed – automatic stop of the saw carriage at the end of the cut – lifting the saw above the cut surface – quick return to starting position– automatic stop of the saw carriage in the starting position.
Auxiliary time is spent on the following operations:
Correct placement of the log on the table;
Log clamp;
Turning of logs, half beams, beams;
Removing slabs, boards, timber from the sawmill table.
The given list of auxiliary operations shows even a non-specialist that specific gravity auxiliary time can significantly exceed sawing time. Therefore, when choosing a productive band sawmill, attention should be paid not only to the sawing process, but also, no less, to the performance of auxiliary operations.
Ensuring high production and quality of lumber in the EU
The main characteristic that directly affects the performance of the sawmill is the power of the main engine. For the EU, the selected power is 15 kW. Practice shows that for high-quality narrow saws (32-50mm), such power is acceptable on sawmills with automatic feed.
Task maximum use The capabilities of a band saw cannot be solved by manual or simple mechanical feeding methods, carried out under the continuous supervision of the operator.
A sawmill without adaptive automatic feeding cannot provide maximum productivity and high quality lumber.
This is exactly the feed provided in the EU sawmill. The operator does not monitor the operation of the saw - the machine itself selects the desired feed speed, at which the power of the main engine is used to the maximum.
The automatic feed quickly reacts to the appearance of knots, expansions (constrictions) of the section, etc. in the cutting line, preventing the saw from “driving a wave.”
No operator is able to react as quickly to changing wood cutting conditions as an automatic feed. It is important that the sawmill control panel is installed permanently, not on a moving carriage, then the operator does not need to constantly run or drive next to the saw unit and adjust the feed. The operator himself is less tired.
Automatic feeding not only improves the productivity and quality of lumber, but also frees up the operator's time during the sawing process to perform auxiliary operations in parallel, without the risk of an accident, and this contributes to higher labor productivity.
The use of hydraulic cylinders in sawmills as band saw tensioners leads to saw breaks and scrap of lumber.
The hydraulics are “dull” and require constant adjustment, i.e. constant attention of the operator. This can be avoided by the presence of a special spring stabilizer in the design of the saw unit, which ensures constant tension on the saw.
The constant tension force does not change when chips and bark get under the guide roller, when the saw is stretched due to its heating, etc.
Therefore, properly prepared saws at EU sawmills “never break”, and the specific net costs for tools due to this can be significantly reduced per 1 m 3 of saw logs.
With such a saw tension stabilizer and automatic adaptive feed, constant attention from the operator is not required - the sawmill automatically provides high productivity without defects!
A productive sawmill should have an automatic setting of the board thickness, which significantly saves time and eliminates the appearance of defective lumber in thickness.
A productive sawmill cannot be floor-mounted!
One of the main design obstacles to achieving high output is the floor-mounted design of the sawmill. Floor table does not make it possible to install remote high-speed mechanisms for working with logs, timber, or boards. Neither a log loader, nor a log and beam tilter, nor quick-acting log or board clamps can be attached to the “floor”. And the working conditions... What does it take to lift a wide multi-meter board with a thickness of 50-70mm, bending to the floor! The EC+ sawmill table is raised 60 cm above the floor level, which allows those working at the sawmill to remove boards in a convenient height area, i.e. quickly, without bending or injuring your back.
Saving auxiliary time on EC
Auxiliary time is significantly saved with the use of a log loader.. The sawmill table height of 60cm is convenient for loading logs from a storage unit equipped with a chain feeder. After turning on the feeder, the log from the storage unit rolls along the folding arms onto the sawmill table, where the stops are previously raised.
Nothing faster and time-saving for loading logs has been invented.
With a log storage facility, sawmill downtime due to the lack of logs and the dependence of sawers on auxiliary workers who supply logs disappear.
Auxiliary time is also significantly saved when using a log tilter. An operation that requires a lot of auxiliary time is associated with the orientation of the log on the sawmill table, i.e. with his turning.
Firstly, if there is a bend, the log must be oriented so that the bend is in a vertical plane. This orientation ensures the greatest yield of lumber.
Secondly, turning a log is a necessary operation when sawing pine. After cutting the log by 1/3, it must be turned 180 degrees, otherwise the failure of the last boards is “guaranteed”. Angling is also necessary when sawing oak - practitioners know this well. To obtain 3- and 4-edge timber, you cannot do without a tilter. Turning a log without a tilter requires not only an increased amount of time, but also a large amount of physical labor.
There are few sawmills that have a log turner. Hydraulic tilters are the most widespread. The disadvantages of hydraulic tilters are the unsatisfactory performance of hydraulics in low temperature conditions and the need to have an operator with high work skills. Fast work with hydraulic tilter - aerobatics for the operator.
An electromechanical tilter not only saves auxiliary time, but also does not require high professional skills!
On the EC, the electromechanical tilter is controlled using buttons: press a button - the log rises above the table level, press another - the log rotates by the required amount, the next press - the tilter gently lowers the log, orienting it to the center of the table. Then, by switching the toggle switch, the log is clamped.
Auxiliary time is also significantly saved due to mechanization for removing the resulting lumber and waste.
The level of labor productivity on horizontal band sawmills largely depends on the method of removing lumber and waste from the sawing area. The EC+ provides the ability to clean both boards and timber both along the sawmill table and across it, without lifting them. There is a board pusher on the reverse stroke of the carriage for thin boards (30mm), a belt or roller conveyor along which the board is moved to the next stage of processing or to the warehouse. In the presence of such mechanization means, the labor of at least one auxiliary worker is saved.
To move heavier (non-lifting) timber, the table is equipped with a pneumatic lift. With the help of lift rollers, the beam is easily and quickly moved along the receiving roller table or across to the storage. This ultimately increases productivity and makes the work of workers easier!
Ensuring ease of operation of the EC sawmill
A productive sawmill must have controls with automation elements. This allows the operator to combine cutting control with auxiliary and maintenance operations.
Low cutting costs are determined not only by the technological equipment of the sawmill, but also by the working conditions of the operator and his assistant. Despite the need to perform a number of physical actions, the worker, manager PLP-EU, is rightly called the operator band saw.
In itself, operating a sawmill is simple and does not immediately require high motor control skills, and, therefore, a lot of time to master. A worker who has previously worked on some kind of “ribbon” can easily master PLP-ASTRA-EC.
Controlling the sawing process takes relatively little time and is carried out simply - using buttons, a feed switch lever and several toggle switches. The control panel is at a convenient height, the indicators are clearly visible. Blocking and restrictions are provided in the control scheme against operator errors. There are limit switches in all necessary places to prevent an accident.
Flow capabilities of the EU band sawmill
PLP-ASTRA-ES is a basic machine for organizing high-performance cutting lines!
The most effective use of the productive sawmill PLP-ASTRA-ES can be achieved when it is included as the first link in the production line or section for the production of edged boards.
The composition of the site equipment (production line) depends on the planned production. To achieve high site productivity, the EC sawmill prepares only timber that is fed via a conveyor to the multi-rip machine.
Unedged boards are moved along other conveyors for trimming to other ASTRA machines. Here it is worth mentioning the high-speed in-line edger SPM-ASTRA-K2, which is capable of servicing 2 or 3 band sawmills.
The advantage of sites organized on the basis of modern band machines is significantly lower installed capacity, significantly lower energy consumption, less wood waste and lower labor costs. Sawing areas of different productivity are presented on the official website of the ASTRA S company.
"ASTRA plus" (Minsk) is the official representative in Belarus of the ASTRA concern (Kirovograd).
The concern unites several machine-building enterprises producing woodworking and metal-cutting machines, special cutting tool and automation tools.
Over more than ten years of operation, the concern has accumulated great experience development, production and maintenance of modern equipment equipped with microprocessor control systems and using high-quality components. Reliability, as well as wide technological capabilities achieved through the use of advanced processing schemes and original technical solutions, made ASTRA brand products popular among woodworkers in Ukraine.
In addition, these machines operate in Russia, Moldova, Georgia, Austria, Guinea, bringing profit to their owners. PLP-ASTRA band saw machines were designed taking into account the experience of many years of operation of sawing equipment. Many mechanisms (non-cantilever pulley supports, eccentric-spring saw tension drive, two-support tilter, scale ruler with automatic adjustment to board size, pneumatic log clamps, automatic feed drive with maintaining a stable load on the saw) were used for the first time in these machines.
PLP-ASTRA-M (productivity - up to 5 m3 per shift)
Floor-mounted base, manual drive feed, manual drive for lowering the saw unit. It is possible to install a scale ruler and a device for securing short logs.
PLP-ASTRA-P (productivity - up to 10 m3 per shift)
Reinforced machine base on legs, remote cable feed drive, automatic installation saws for the size of the board being cut, load control on the saw, additional end clamps of the workpiece. It is possible to install a tilter, a debarker, a device for securing short logs, pneumatic log clamps, and an aspiration system.
PLP-ASTRA-E (productivity - up to 12 m3 per shift)
Reinforced base of the machine on legs, automatic continuously adjustable feed drive, ensuring maintenance of a given stable cutting force and accelerated return of the carriage, electromechanical drive for lowering the saw unit with automatic adjustment of the saw to the size of the board being cut, control of the load on the saw, additional end clamps of the workpiece. Additionally, it is possible to install a tilter, a debarker, a device for securing short logs, pneumatic log clamps, and a hinged aspiration system.
PLP-ASTRA-ES (productivity - up to 15 m3 per shift)
Reinforced base of the machine on legs, saw drive power 11 kW, saw width up to 50 mm, automatic feed drive, providing smooth regulation and maintenance of the specified cutting force and accelerated carriage return, automatic adjustment of the saw to the size of the board being cut, load control. It is possible to install a tilter, a debarker, a device for securing short logs, high-speed pneumatic clamps, and an aspiration system.
Each of these machines includes 2 saws. The efficiency of the machines increases with the use of the following suggested additional devices:
- The mounted active aspiration system ensures reliable removal of chips and dust from the cutting zone, which allows you to operate band saws indoors, observing sanitary standards. Mounted on the machine carriage.
The two-support electromechanical log lifter-tilter is designed to lift the log above the machine bed and rotate it (tilting). The log or beam can be easily rotated to any required angle without damaging the surface and lowered onto the frame.
A device for quick parallel fastening of two short bars is easily installed on the machine bed and provides quick fastening end clamps of logs from 0.5 to 2.2 m long.
Pneumatic log clamps provide quick log clamping and maintain clamping force during sawing. Facilitate the work of staff and increase sawing productivity.
The bark-cleaning attachment (debarker) is designed to clear the bark from a log at the point where the saw enters it. Allows you to increase the durability of saws when sawing logs with contaminated bark. Installed on the frame of the saw unit of the machine.
Director of ASTRA Plus Vyacheslav Zhukov is confident that the equipment that his company demonstrated at the Woodworking exhibition represents the best offers in this industry in the CIS.
Prepared by Sergey ZOLOTOV
Before using the machine, carefully read its rules and operating procedures. General information About the sawmill and the operating instructions are given below.
FAQ.
Question:
good evening, I have T2B sawing great, people like it, but for the second year in a row at minus 5-10 degrees he doesn’t want to cut, or rather the tape flies off the saw wheels last year I was forced to stop production for the winter, but this year I don’t want to check the alignment, everything is in order to lubricate the belt I use wax mixed with oil, what could it be? It can increase the tension of the tape, but I’m afraid it will start to tear the tape, tell me what to do and what to do
Answer:
Hello Alexey! As soon as any oil-based lubricant appears on the saw wheels, the saw will fly off. When sawing in winter, people use either diesel fuel or pure form, or “anti-freeze”.
Question:
how to install a 3-section rail track evenly to avoid smooth sawing boards and other nuances
Answer:
Hello Vitaly. When installing rail tracks on the Taiga sawmill, it is enough to use a building level and, thanks to it, fix the adjusting supports at the proper height. Periodically check the height of the rail track at the same level and the boards will be level.
Band sawmill model PLP-ASTRA-EC
Band sawmill model PLP-ASTRA-EC is a semi-automatic band saw with:
- automatic feeding of the band saw device;
- automatic setting of board thickness;
- a mechanized table for working with logs;
- control of all technological operations using buttons.
Thanks to minimal fuel consumption, ease of use, proper performance and enviable practicality, a powerful and high-quality petrol tire sawmill looks ideal option for producing container slats, veneer, thin gauge, multi-profile timber, edged/unedged boards or carriages. In addition, a gasoline tire sawmill is indispensable and extremely effective in places with no or limited electricity supply.
A modern electric bus sawmill ensures low power consumption. In addition, unlike a gasoline-powered model, an electric tire sawmill does not require refueling. A chain sawmill can guarantee fairly high cutting quality and silent, productive work. High environmental safety is also considered to be one of the basic advantages that traditionally characterize the chain sawmill.
As we see, ideal solution for fast and efficient sawing wood is a sawmill. Thanks to its long-lasting, maintenance-free operation, its portability, compactness and stunning appearance, the tire is understandably in demand in today’s market. Regardless of the modification you choose, the tire sawmill will delight you with wonderful performance and reliability. Our company has been successfully operating in the market since 2006.
The product has proven itself well high speed, cutting quality, compactness, reliability, cost-free installation and setup, quick commissioning and low price. Installation and installation can be done either independently or with the participation of specialists from the manufacturer.
All products are covered by a two-year warranty.
The standard electric bus sawmill has a power of 5.5 kW, 380 V. The length of the log is 6.5. Diameter up to 50 cm. Cut thickness 6 mm. Feeding and setting the size manually.
Cutting tool – tire 20", 1.3 mm, 3/8". Productivity is about 2.5 cubic meters of edged boards per shift. Tire sawmills are universal machines for processing round timber and allow not only to obtain boards of any size, but also to process unedged material into edging into timber, picket fences, glazing beads.
Sharpening and cutting tools for tire sawmills can be purchased at any specialized retail store. Transportation of the entire sawmill is possible on a regular passenger car, on the trunk. The weight of the entire structure does not exceed 160 kg.
LB-80
These sawmills have proven their reliability and unpretentiousness in operation.
The Astra sawmill allows you to saw short logs (up to half a meter) and obtain thin boards (up to 5 mm thick). The LB sawmill does not require a special foundation; it is installed on solid, level base within 1-1.5 hours. The room in which the sawmill is operated must comply with class P-2 according to the PUE. The machine is designed to work in conditions of UHL 4 according to GOST 15150-69.
Are common : 
The log band saw machine LB-80 (hereinafter referred to as the sawmill) is designed for straight sawing of workpieces with a diameter of up to 80 cm and a length of 0.5 to 6.5 meters. It is used as blanks without preliminary sorting by diameter and quality. The sawmill allows for individual cutting of logs and their parts in accordance with wood quality zones, obtaining higher quality lumber from low-grade raw materials. It also allows for rational cutting of valuable and hard wood.
Sawing in a horizontal plane with the Astra sawmill while the log being processed is stationary allows you to:
* reduce material waste by 2-2.5 times;
* obtain impeccable quality of the processed surface;
* ensure processing accuracy +2 mm at a length of 6 meters;
* reduce operating and energy costs;
* quickly rebuild the sawmill to the desired (exact) size.
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Description
Band sawmill PLP-ASTRA-ES+, one of the few band sawmills built into the flow.
Features: The band sawmill is combined in line with a multi-rip machine and especially with a semi-automatic longitudinal saw (edging machine) SPM-ASTRA-K2.
This combination of woodworking equipment (band sawmill, multi-saw machine, edger) together with a system of transfer and loading and unloading devices allows sawing up to 40 m3 per shift. round timber on edged board two operators and two auxiliary workers.
One band sawmill PLP-ASTRA-EC+ due to the mechanization of the table - drive tilter, pneumatic log clamping, pneumatic lift-roller table, for end unloading of logs, mechanization of log loading and semi-automatic manipulator, automatic feeding, automatic setting to size, ease of control (buttons) per shift provides sawing of up to 20 m3 of wood.
Sawing up to 20 cubic meters m of roundwood is determined by the following factors. Pure time for sawing under normal production conditions for sawmills operating narrow saws (up to 50 mm) is up to 30% of the total operating time. The remaining 70% or more of operating time is occupied by auxiliary time. This is where the main performance reserve lies:
2. The log is rolled onto the sawmill table and centered by slightly lifting the tilter.
3. Fixing the centered log with pneumatic clamps by simply pressing a toggle switch.
4. The necessary tilting of the log is carried out without manipulating the levers, as on most sawmills that have a tilter. The procedure is simple:
- pressing a button - the log rises above the frame in a few seconds;
- pressing a button - the log is rotated by chain grippers to the desired position of the sawn face in a few seconds;
- pressing a button, the log is lowered onto the table with its face or other surface in a few seconds.
When working with an electromechanical tilter:
- there is no impact of the plate on the table, which allows its accuracy parameters to be maintained;
- no high operator skills required;
- a significant portion of auxiliary time is saved;
- no physical effort required by the operator or assistant;
- complete work safety.
5. Removing a board or timber from the sawmill table is done using a manipulator without any physical effort.
The operator's job is to:
- while cutting, grab the board or beam with a manipulator;
- upon completion of the cut, after the limit switch is triggered, turn on the feed of the manipulator to pull the board together;
- after turning on the feed of the manipulator, enable the accelerated return of the saw unit to its original position. In this case, the board removal speed exceeds the saw unit return speed. This is especially important when removing boards more than 50 mm thick and timber that is very heavy. Combining board removal with carriage return significantly saves auxiliary time. Boards and beams are removed onto a roller table, which can be the entrance to a multi-saw or a semi-automatic edge trimming machine, or to both machines at the same time, i.e. timber - in multi-saws, boards in edge-edging.
6. The mechanized table is also equipped with a centralizer for preparing 3-edge or 4-edge timber, which saves auxiliary time.
7. To remove very heavy timber, a pneumatic roller conveyor is mounted into the mechanized table, so as not to pull the timber directly along the table.
Automatic continuously adjustable feed does not require operator control over the sawing process. The force on the saw is controlled and the feed changes automatically: when passing through knots, it decreases, after passing through, it increases to optimal value, which does not lead to the appearance of waves on the board.
Due to the automatic feed, the saw is not overloaded, and therefore does not produce waves when cutting. The absence of overload on the saw, in addition to the smooth operation of the spring tension mechanism, contributes to the long service life of properly prepared saws. One saw, as a rule, produces at least 70-80 m3. During sawing, the operator performs auxiliary operations - prepares the next log, removes boards and waste, and makes calculations for the optimal cutting of wood.
The band sawmill PLP-ASTRA-EC+ combined into a production line with a semi-automatic edger SPM-ASTRA-K2 allows the production of up to 2 cubic meters per hour of export-class edged boards, and the combination of PLP-ASTRA-EC+ and SPM-ASTRA-K2 and The multi-saw machine doubles the output of edged boards.
Technical characteristics - Band sawmill PLP-ASTRA-ES plus
| Main settings | Values |
|---|---|
| Log diameter, mm | |
| without tilting, mm | 800 |
| with tilting, mm | 1000 |
| Thickness of sawn timber, mm (no more than) | 220 |
| Thickness of sawn board, mm (no more than) | 2 |
| Board length, mm | 1200 … 4500 / 6200 |
| Sawing accuracy, mm (not worse) | 0.5/1000 |
| Pulley diameter, mm | 600 |
| Band saw, mm | 4270 ± 30 x 32 ... 50 |
| Cutting speed, m/s | 35 |
The ASTRA-EC band sawmill cuts wood into edged or unedged board, or into timber with a sawing capacity of 16-18 m³ lumber per shift. The ASTRA-EC sawmill does not drive waves, does not tear saws and works reliably at negative temperatures. Easy to operate, does not require large maintenance costs, since components and consumables are available on any market.
The basic package of the ASTRA-EC sawmill includes a frame with working part 4.5 m or 6.2 m (any length can be made to order), saw unit, control panel, automatic continuously variable feed drive (automatic scanning of the load on the saw and slowing down the saw unit on branches and other difficult areas with changed wood structure), automatic installation to the size of the board being cut (accuracy 0.5 mm), log clamp system. When installing an additional auxiliary equipment, the productivity of the ASTRA-EC band saw machine increases significantly.
The saw unit has continuously variable feed drive and 9 cutting modes for various types and the state of the wood - dry or damp, hard, soft, frozen or unfrozen. During operation of the saw unit, its speed is automatically slowed down on branches and difficult areas, so that the band saw is not overloaded, does not give a wave and does not tear when sawing.
Unlike hydraulics, the ASTRA-EC sawmill is equipped with spring saw tension mechanism, which has proven itself, working in the cold season at very low temperatures. The absence of overloads and smooth operation of the spring saw tension mechanism contributes to the long service life of properly prepared saws. When the saw is heated, there is no need to monitor its tension, which significantly reduces the influence of the “human factor” of the operating personnel. One saw, as a rule, produces at least 70-80 m³ of roundwood.
Double-sided fit of duralumin pulleys large diameter- 600 mm, allows you to easily accelerate them to the desired speed, avoiding power surges in the network and quickly stop them, ensuring their stable high-speed operation without excessive load on the bearings, extending their service life and also saving the life of the saws.
Additionally can be installed on the ASTRA-EC sawmill hanging system aspiration, device for fastening the shorts, debarker for cleaning the cut line, driven two-support semi-automatic or automatic log tilter, pneumatic log clamps, pneumatic roller conveyor for end loading of logs and unloading massive half-beams or beams onto a multi-saw machine, drive roller conveyor storage for mechanizing log loading, linear laser cut line indicator (more accurate positioning).
Sawing line, which includes an ASTRA-EC band sawmill and a multi-saw machine ASTRA-R3, multi-rip edger ASTRA-K2 and a system of transfer and loading and unloading devices, sawing up to 50 m³ of round wood per shift for an edged board by two operators and two auxiliary workers.
The ASTRA sawmill is manufactured on the basis domestic components and is complemented by a device for automatic sharpening/setting of band saws, as well as a device for tensioning belts and replacing bearings in pulleys, which greatly facilitates independent maintenance of this band saw machine. The ASTRA-EC sawmill is reliable in operation and easy to maintain.
The standard warranty for the ASTRA sawmill is 12 months.
Specifications sawmills ASTRA-EC: