Our Process
The process begins with receipt of approximately 120 log trucks each work day. That is a lot of trees, and we are proud of the fact that our parent company has continually planted more trees than were harvested since the 1930’s. A 20 ton crane not only unloads trucks, but rotates stored log inventories and feeds the Log Processor. The Log Processor begins with debarking the logs, which is followed by an optimized scanning process prior to the logs being cut into 10′ through 20′ lengths, which are transferred to the sawmill for processing. Each tree length stem is cut into pieces in order to maximize the amount of lumber that can be processed from the geometric shape of each shorter section of log.
No part of the tree is wasted. Bark, sawdust and even vines that are tangled in truckloads of logs are processed and utilized as residual products for industrial fuels and landscaping materials. There is no waste in any of the processes throughout our facility. Once a log enters the primary or large log side of the sawmill, it is scanned by another optimizer and is automatically rotated to maximize lumber production. It is then processed by a Log Canter that chips off opposing sides of the log before passing through a twin-band saw, where side boards may be removed. Prior to entering the Curvesaw Gang, each canted log again passes through another optimizer and sawn into individual pieces of lumber. The Curvesaw Gang maximizes the amount of lumber obtained from each log by sawing along any natural curvature in the log stem. Boards are then transferred to a lumber deck for further processing.
The small log side of the sawmill operates similarly, but is a bit more streamlined. Smaller logs, generally with less than 10 inches in diameter on the large end enter the mill, are scanned by an optimizing scanner and rotated to maximize lumber production. They are initially squared on both sides with side boards being removed if needed. A second machine then processes the top and bottom of the cant, or log. Sawn boards are transferred to a different portion of the lumber deck utilized by the large log side of the process, and all are ultimately sorted by thickness, width and length. The last steps in the sawmill process are to trim each piece to specific lengths and then sort and stack like sizes into Rough Green Units that have spacers between each layer in order to promote uniform drying in our dry kilns.
Lumber drying, which reduces moisture content to industry standards of 19% or less, is accomplished in one of three new, state-of-the-art Dual Path Continuous Dry Kilns. This type of dry kiln continually pushes Rough Green Units of lumber through three distinctly different chambers within each kiln, which ultimately provides a consistent final moisture content while minimizing lumber defects associated with heating. The dry kiln’s heat source is derived from burning sawdust, which is the sawmill’s lowest valued residual commodity and is a Green fuel. Following drying, Rough Dry Units of lumber are processed at the Planer Mill, where each board is dressed, or smoothed, to exacting specifications. Every piece of lumber is then assessed and assigned a grade by another piece of state-of-the-art equipment, a Lucidyne Lumber Grader.
Lucy, as she is referred to, is a sophisticated series of “artificial intelligence” computers that have been trained to scan our southern pine lumber and assign appropriate grades to each commodity that we produce. Every board is double checked by a certified lumber grader and is trimmed to a specific length before it is sorted by length and grade and is packaged by an automated system.
Finished, packaged lumber is then stored in one of the multiple dressed lumber sheds to await shipping after LFP’s experienced Sales Staff sells it to one of the broad based customers. Shipping alternatives include being delivered by rail, contract truckers and Lanco Trucking, Inc., which is another “sister” company that resides under The Langdale Company’s corporate umbrella. Langdale Forest Products Co. is proud to have the heritage of being a part of The Langdale Company and share its motto of Quality and Service, Since 1894. Wood procurement and manufacturing personnel are supported by a broad cadre of in-house electrical, fabrication, maintenance and staff professionals, all of which continually strive to earn our customer’s confidence, respect and business.
