Mayer sawmill, Germany
Value optimization at the logyard
Especially in economically challenging times, the premise of achieving the maximum value from each log is even more important. To guarantee this, Amanda Software relies on value-oriented optimization. This is now also used for the classification of cross-cuts on the roundwood sorting and transporting carriage (RSTW) from Baljer & Zembrod. The southern German mechanical engineering company has been the exclusive distributor of the software solution since the beginning of the year 2025. The Mayer sawmill in Rainau, Germany, which has had a new RSTW with optimization software since 2024, is delighted with the technology.
The sawmill in Rainau was first mentioned over 850 years ago. Today, around 12,000 cubic meters of timber are cut each year on the Ostalb. In addition to spruce, fir, larch, Douglas fir and pine, oak and beech are also processed. The company cuts logs up to 65 cm in diameter at the fence, larger diameters are stored and cut once a year using a mobile band saw.
In recent years, the company has continuously invested in the site - including the log yard: since last year, the sawmill has had a new roundwood sorting and transporting carriage (RSTW) from Baljer & Zembrod. According to owner Johannes Mayer, the reason for the investment was to bring the process at the log yard back up to the state of the art: "Until a few years ago, my father was responsible for sorting the logs and decided which log was to be cut and how. This was no longer feasible for my employees and me in this form. With the new investment, we can now carry out this work step much more efficiently.
A trusted supplier
Even before the new RSTW was delivered, the family-run company already had an older model of this type of machine. The logs can be measured, cut, sorted and fed to the saw with just one operator. The comfortable, fully glazed operator's cabin enables a good overview of the log yard. The crane has a reach of around 14 m. As the family business had already been working with an RSTW from Baljer & Zembrod, the existing 3 m wide track system could continue to be used. The hydrostatically operated RSTW can be infinitely accelerated up to 140 m/min
Optimized cuts
After Mayer had once again opted for an RSTW from Baljer & Zembrod and was awaiting delivery of the machine, he heard about the optimization solution from software developer Amanda Reiter and wanted to have it implemented in his machine. After positioning the logs, which can be up to 19 m long, on the cross-cut log deck, a 2D measuring system moves over the log and determines its length and diameter. So far, so normal: recently, this data has been used to calculate a 3D model of the log. The Amanda software determines the optimum log lengths and cutting patterns. The calculation is based on the existing orders, which can be imported from TiList, Amanda Software's ERP system, or other systems. From these, the software generates timber lists with all currently available production quantities and determines suitable cutting patterns for the various assortments to be produced. "In contrast to conventional optimization by pigtail and length, this software calculates the maximum yield per cubic metre. The operator can then choose from five optimization variants," explains Reiter. "The crucial point is the optimization based on contribution margin using AI. For example, asymmetrical cutting patterns can also be created and a significantly more efficient cut can be made," explains Baljer & Zembrod Managing Director Peter Schaeidt. According to Reiter, the value-oriented optimization achieves an additional yield of up to €10 per cubic metre (in the scenario that the logs are virtually sold in their entirety). Once the operator has decided on an option, the Holtec ES 124 sawing unit makes an initial cut to determine the log quality. Further cross-cutting of the long timber takes place automatically. The logs are then either transferred to a butt-end reducer, also from Baljer & Zembrod, stored in a buffer area or fed directly to the saw frame. The RSTW is equipped with an automatic labeling device on the front for better identification of the log sections. Fixed lengths are also available for optimization; these are also priced and stored in boxes
Paperless workflow
"Since the introduction of the software, we have been working nearly paperless throughout the sawmill. The orders are entered directly into TiList and the RSTW operator then receives the production data in real time. The operator at the log yard can see any changes to the orders immediately and can react accordingly. We also rely on the software solution from Amanda Software in the planing mill and for order picking and invoicing. All work areas, such as forklifts and saw frames, are equipped with tablets," explains Mayer. Since then, the entire company premises have had a comprehensive WIFI connection
Further Installations
In addition to the successfully implemented project on the Ostalb, Baljer & Zembrod is also in the implementation phase of the Reiter software at Reinthalmühle, Straß im Attergau (Austria), where an RSTW and a milling head debarker were installed in 2022. "As a leading provider of handling solutions for medium-sized companies from our own production, the exclusive distribution of the Reiter software is an attractive addition to our product portfolio," Schaeidt is convinced and emphasizes that it can be retrofitted to all RSTWs of the latest generation.
Source: Holzkurier
Text: Jakob Wassermann
Photo: J. Wassermann and Baljer & Zembrod
Picture 1:
The Mayer sawmill was able to use the existing track system for the all-electric RSTW.
Picture 2:
Successful project implementation: Peter Schaeidt (Managing Director Baljer & Zembrod), Amanda Reiter (Amanda Software), Johannes Mayer (owner of sawmill Mayer), Karl Heinz Würtele (technical sales Baljer & Zembrod) and system operator Martin Rief (from right)
Picture 3:
Five optimization variants are suggested to the operator of the RSTW for the log.
Picture 4:
Each log is measured using a 2D measuring system. This data is used to create a calculated 3D model, which forms the basis for optimization.
Pictre 5:
In addition to the Mayer sawmill, Baljer und Zembrod is currently implementing the Amanda software for the RSTW at Reinthalmühle in the Hausruckviertel region of Upper Austria.
