FCOS Airflow Evaluation

JBW Consulting was retained by one of our wood manufacturing clients in Sagola, MI to investigate an issue the facility was experiencing, where large flakes were not getting fully evacuated from the Flying Cut-Off Saw (FCOS). After discussing further with the facility’s personnel, this investigation was driven by a Flake-On-Face issue. It was JBW’s understanding that a Flake-On-Face is a flake that gets pressed into the face of the board during the pressing process. If this occurs, the board does not meet the client’s quality standards and is rejected.

JBW traveled to the site and collected airflow readings, videos, and photos of the saw operation and discussed the FCOS issue with plant personnel. Additionally, while on site, JBW investigated the Flake-On-Face issue by observing the operation of the Paper-Overlay system, Press Loading system, and the Press.

It was determined that the airflow in the duct did not seem to be contributing to the Flake-On-Face issue. Additionally, JBW contacted the FCOS Cyclone and Fan vendors to determine if the equipment could handle more airflow. It was found that the flake collection ability of the cyclone could possibly improve with a 2,000 CFM increase in airflow. In order to get the 2,000 CFM increase of airflow in the cyclone, it was determined that a new fan would be needed.

JBW delivered a findings memo to the client for further decision making that included the air testing readings, recommendations for a new fan to increase the airflow and recommended that the client place cameras around the equipment to capture any flake movements in the Press area to locate the exact source the flakes were coming from.