WOOD UTILIZATION RESEARCH CENTERS
A USDA Special Research Grant
EXAMPLES OF RESEARCH SUCCESS AND IMPACTS
New technology from WUR
research to detect knots in softwood lumber and enable automated lumber grading
or cut-up has been successfully installed in window and door part cutup plants
and sawmills. One manufacturer
reports a wood yield increase of 4% worth $2,000,000.
(MISSISSIPPI)
Higher density wood
species such as oak, which are widely available in the eastern U.S., have not
been used in the manufacture of oriented strand board (OSB). WUR research is overcoming the quality
and engineering challenges to use oak, thus allowing for new or expanded plant
facilities to manufacture OSB, increased utilization of low-value materials,
and increased employment.
(West Virginia)
WUR supported training
on lean manufacturing to over 75 companies and continuous improvement projects
with 15 companies resulting in productivity improvements that saved over
$750,000 and strengthened company global competitiveness. (MINNESOTA)
WUR funding is being used for
the design and building of blast-proof wood-hybrid materials for protection of
our troops in Iraq, Afghanistan and worldwide. WUR support was leveraged to
build the Advanced Engineered Wood Composites Center at the University of Maine
and further, to develop our capacity for Disaster Resistant Housing which in
turn has lead to the development of rapidly deployable structures for military
use and the production of ballistic panels currently being used and tested in
Iraq. (MAINE)
WUR research efforts have resulted in dramatic
productivity and wood utilization improvements for computer controlled routers
used in the manufacture of upholstered furniture. The development of high
speed spindles using smaller diameter tools has resulted in up to 5% wood yield
improvements. High speed, high power spindles can also process multiple
sheets which can easily double productivity. Application of these
research results has had a dramatic effect on the global competitiveness of
U.S. based manufacturers. (NORTH CAROLINA)
The total harvest of timber in
the U.S. is currently about 15.5 billion cubic feet, with an estimated standing
tree value of $15 - $20 billion. WUR funded research has shown that new
harvesting-related sensor technologies, optimization systems, and
equipment design can increase log value by 20% and reduce
harvesting/transportation costs by 10%.
Conservative estimates of the increased net returns to the forest sector
nationally are $2.5 billion per year, independent of the benefits of increased
mill recovery from improved matching of log properties with market needs.
(Oregon)
Three Alaska tree species (yellow cedar, spruce
and hemlock) were assigned specific new grade stamps based on WUR research. This work demonstrated that Alaska wood may
be sold as a unique structural lumber product with higher strength values than
non-Alaska materials. As a result, Alaska wood producers can reach new markets
and command 10-15% higher prices than competitors. (ALASKA)
A major forest product
company invested $600,000 to use WUR research to improve the environmental
behavior of paper bleaching technology.
As a result, the company was able to improve lignin removal from
softwood pulp, reduce operating costs and lower pollution load, thus making the
mill more economically competitive and able to retain jobs. (MAINE)
Hardwood log bucking and
merchandising practices were investigated throughout West Virginia. WUR researchers developed a 3D optimal
bucking system and showed that using this tool could gain harvesters 26 to 43%
more value per tree stem. (WEST
VIRGINIA)
WUR research has
identified and tested several formaldehyde-free binding systems that can be
used in manufacture of wood-based composites such as plywood and particleboard. These new technologies enable U.S.
manufacturers to produce competitive products without toxic formaldehyde
emissions and reduce dependence on petroleum-based adhesives. WUR research laid the foundation for
later competitive funding that resulted in technology for a successful new line
of composite panel products.
(MICHIGAN, OREGON)
Sawmills adopting WUR
research on high-temperature drying of grand fir lumber have realized a 200
billion Btu annual savings in natural gas and wood energy. This is a savings of approximately 20%
of all energy used at those plants and is equivalent to 5.5 million cubic
meters of natural gas, or enough energy to heat over 2,500 homes in Idaho each
year. (IDAHO)
WUR researchers partnered with five small and
medium-sized wood products companies in Minnesota to create new and innovative
wood products. WUR supported assistance and research enabled the
companies to add new product lines and expand production as a result of their
improved competitive market position.
As a result, annual sales have increased by $15 million and over 200 new
jobs have been created since 2000. (MINNESOTA)
Data generated through WUR
research on volatile organic compound and hazardous air pollution emissions is
now being used at many of the estimated 3,000 hardwood and softwood mills in
the eastern US states saving each mill $35,000 for each kiln in compliance
testing. (MAINE)
WUR research developed
an innovative system to improve quality in the manufacture of medium density
fiberboard (MDF). Over a six-month
period, one plant documented cost savings of $700,000 from reduced wood and
resin consumption. (TENNESSEE)
WUR research
demonstrated that volatile organic compound emissions from lumber dry kilns
could be measured with $25,000 less cost per kiln than proposed by
environmental regulators. This work saved lumber manufacturers over $15,000,000
in Oregon alone. (OREGON)
Wood-plastic composite
(WPC) material formulations developed with WUR support are used in about 1/3 of
the entire North American WPC production. (WASHINGTON)
WUR research developed a new
real-time system using statistical process control (SPC) to reduce sawing
variation during hardwood lumber manufacture. The system worked directly with hardwood
lumber manufacturers and resulted in costs savings of $1.29 million to the four
producers that tested the real-time system. Hardwood lumber producers partially
supported the project by providing $76,000 in direct support (TENNESSEE AND NATIONALLY)
Over 50 future
scientists and practitioners are trained each year through graduate degree
programs supported by WUR research. (NATIONALLY)