Replacing an 1980s manual stop-n-chop bucking system with a modern Gen 7 Sliding Infinite Trim (3) Saw Log Trimmer System — complete with 3D scanning to maximize value recovery — this project added optimization, accurate trimming lengths, and increased throughput for Varn Wood Products in Hoboken, GA.

Varn Wood Products needed to modernize their log merchandising system to match the investments they had already made throughout the mill — and to remain competitive. One of the core challenges was building the new merchandising system while the mill remained in operation. Working closely with the mill team, a solution was found: the new log trimmer system would be supplied offline, while the existing log handling system downstream of the merchandiser would be retained for the time being — presenting a clear opportunity for a second upgrade in the years ahead to maximize ROI.

Mill management also requested a solution for feeding the mill with a minimum gap to increase productivity, without having to raise processing speeds and induce additional wear on the equipment.

We replaced the older stop-n-chop system with our Gen 7 log trimmer. The new system utilizes traveling saw carriages with infinite trimming capacity to fully leverage 3D lineal scanning technology — far superior to the legacy system in both recovery and performance. Its compact footprint made it possible to install offline while the mill continued running.

In addition to the new log bucking line, we collaborated with the mill on the supply of a screw primary log feeder. This solved the gap-control challenge — giving the mill precise, controlled feed to the primary and allowing them to push production limits safely, while reducing wear and tear on the primary turning rolls and drive systems.

The combination of accurate bucking, optimization, increased production, engineered gap control, and single-operator control delivered a strong ROI for the project.

With the 2023 log trimmer delivering measurable production gains, Varn Wood Products needed to modernize the downstream log handling system to match — fully realizing the ROI of Phase One. Mill management was aggressive and innovative: they requested a fully automatic, safe system requiring minimal operator interaction in feeding the mill.

Working alongside an industry consultant and a PLC/scanning vendor, we settled on a layout and equipment solution that would bring the entire line up to the standard set by the new trimmer.

We replaced the old log handling system with pocket pushers, kickers, log decks, and a Strenx step feeder — while retaining the original screw feeder to the primary breakdown. The new system incorporates a log sorting line with 3D scanner, butt reducer, ground discharge and refeed systems, and extended log storage feeding the primary line.

This solution is far superior to the older system in production, efficiency, and safety. Like Phase One, the new system was designed for a compact footprint and installed offline while the mill remained in operation.

Together, the 2023 log trimmer project and the 2026 log handling project delivered a compelling combined ROI — transforming Varn Wood Products into a fully modernized, high-throughput operation from end to end.