hhopper@littlecolorado.org

Project summary: This project is a collaborative effort with two localbusinesses LB International of Winslow, AZ, and Alpine Trucking andSpecialty Woods of Eagar, AZ. Funds were used to implement specializedmanufacturing machinery training techniques for expansion of production of smalldiameter forest products. Alpine Trucking purchased a state-of-the-art JacksonScragg Mill and trained about 25 employees on its use. LB International isdeveloping an expanded production facility for a biomass heating and cookingproduct (called Pure Blaze); LBI trained five employees in machine operationsand production safety. The Arizona Sustainable Forestry Partnership assisted inthe grant administration and recording the results of the project. Additionalpartners for this project included the Town of Eagar, the U.S. Fish and WildlifeService, The USDA Forest Service, the cities of Winslow and Springerville, theUniversity of Arizona Cooperative Extension, the Little Colorado River PlateauRCD and the Cocopai RC&D. In essence then, this project seeks to take thestudies and assessments of forest health and revitalization to the next level,economically applying resource management prescriptions and creating newemployment in the manufacture of small-diameter forest products. The grantenabled the purchase of equipment that will, in turn, promote the development ofnew types of forest products for consumers; provide training and new managementskills in the operation of that equipment; to ultimately promote the region as aprime location for a new breed of ecologically-beneficial forest resource-basedenterprises

Project goals:

Results to be achieved include: Technological advancements through the purchase of specialized efficient equipment. Specialized workforce training and development. Implementation of new and innovative management and/or sale contracting methods.

Criteria for success includes: Purchase, set-up and operation of highly specialized equipment. Implementation of job training program, ultimately creating 35 new positions.

Time frame includes: Project will commence implementation by May 15, 2000 and be completed by December 31, 2002.

The Arizona Sustainable Forestry Partnership is a collaborative effort ofdiverse stakeholders that have met on a continuous basis since 1996. Thecollaboration develops and coordinates projects that will introduce a newsustainable forest industry in Arizona. To a great extent, this has beenaccomplished as a result of the organizations efforts to define resources,coordinate activities and bring diverse interests together at the negotiationtable. This "action team" is comprised of over 100 members and ishosted by the Little Colorado River Plateau RC&D of Holbrook, AZ.

Alpine Trucking and Specialty Woods, Inc.

In 1999 Alpine Trucking and Specialty Woods, Inc. was formed to address thechallenge of utilizing small diameter timber resources, predominately from theNational Forest lands in the southwest, and processing these materials into avariety of value added products. As is the case with many companies facingdramatic industry conversion challenges, Alpine went into this effort with agreat deal of "hands on" knowledge of timber and limited capitalresources. The company was a forerunner in the design and implementation of alog sorting and merchandizing facility, for example,

Based upon research conducted by the company, it became evident that if thecompany were to remain competitive and profitable, it would require increasingproduct diversity and the integration of advanced, specialized equipment.Coupled with this was the acknowledgement that Alpine would need to implement arobust workforce development and specialized training program. The companydeveloped an expansion plan that included moving to a new facility; a 50 acresite in the Springerville Airport Industrial Park. The cornerstone of this movewas the purchase and installation of a used "state-of-the-art" squarewood processing mill, called a Jackson Scragg mill. This is a small, uprightdevice with two 36" adjustable blades that takes round logs and turns theminto construction lumber. It is portable, which means it reduces the number oftimes small diameter material must be handled once it is harvested, therebyreducing the processing and handling costs. This added equipment promised toincrease the companys production capacity and allow for it to efficiently andeconomically process available small diameter material from the forests. Thismill, manufactured by the Morgan Saw Company, was subsequently purchased (for$18,000) in August 2000 from a mill operation in Juarez, Mexico. An ambitioustraining program began shortly thereafter.

Phase I training cost $17,310 for 20 days of formal instruction, conducted atthe manufacturers facility in El Paso, Texas. Seven employees underwent thistraining, accompanied by two supervisors, who also received managementinstruction. This training was all "certified" (as it was provided bythe actual manufacturer) and included instruction on the latest safetytechniques. Four Corners Sustainable Forests Partnership grant funds financedthis training and travel expenses. Training was completed on October 23,2001.Eventually, another eight employees were trained in this equipment by thosethat attended the training at El Paso.

Phase II commenced shortly after trained employees returned to Eagar. Alpinequickly discovered that the Scragg mill would not live up to expectations. Earlyoperation uncovered the fact that extensive modification would be necessarybefore the mill could perform to standard. The maintenance package of oils andlubricants was quickly used up, as each modification required a new investmentof moving parts and pieces. In the subsequent months of 2001, Alpine found itsdays consumed in more modifications and adjustments. What at first was believedwould be an ideal piece of equipment for process small diameter timber, wasrapidly becoming an equipment and maintenance nightmare. During the summer of2001, Alpine Trucking and Specialty Woods, Inc, made the decision to move theiroperation across the state line, to Catron County, NM.As this move wasinitiated, Alpine was still debating the merits of taking the Scragg mill withthem. When last contacted, general manager chuck Jimenez was quoted as saying,"The Scragg mill never did perform up to expectation. In fact, we had tomake so many modifications that the final product barely resembled the originalequipment. In retrospect, it was not a valuable use of our time andeffort." We conclude from his efforts that the Scragg mill may not be thebest equipment when working with Small diameter timber.

Alpine trucking and Specialty Woods, Inc, is currently re-evaluating itsbusiness goals and plans, possible pursuing another, different product line.Their last phone number was 520/333-4614.

LB International, Inc.

LB International, Inc. (LBI) is a developer and manufacturer of environmentalproducts. Its core product is a densified log made from any number of recycledmaterials, including newsprint, telephone books, olive pits, cotton trash andwood chips from small diameter forest material. The "PureBlaze" logsinclude a soy wax coating for the bottom which holds the material together andmakes it easier to light; a typical log can burn for about three hours andproduce more heat than a comparable amount of wood. The company has developedand test marketed a line of these logs, which range in size from ten pounds, toa "six pack" of 2.5 pound logs. LBI is the first area company toexpand into the commercial application of practical and functional heating andcooking products made from recycled material. Located at the Eco-Lena BusinessPark in Winslow, AZ, LBI leases over 50 acres of land that it eventually hopesto transform into a forest product processing facility. LBI can be reached at1294 S. Hwy 87, Winslow, AZ 86047, 520/289-5634.

The companys principals have invested additional funds to further expandproduction capabilities and facilities. Company management, Jim Lehmann and MikeCasebier, subsequently identified equipment and training programs that wouldenable the company to achieve these new production goals. Specifics of theequipment follow.

The Dura Tech Model EC-900 Industrial Tub grinder. Powered by a 150 HPToshiba electric motor, purchase price for a used piece was $73,060. The tubgrinder is capable of grinding 10 tons of waste per hour into small particles. Aset of rotating "hammers" spin at approximately 1700 rpm. Wastematerial is loaded into the top of the unit and, after grinding, the materialfalls through screens to the bottom, where forced air pushes it further down theprocessing line. LBI experimented with various modifications. For example, theyinstalled different hammer types and sizes and different screens, permittingthem to grind much larger material, up to eight-inch trees. Furthermore, LBIinstalled more efficient auger system to replace blowers and cyclones (used topush material along the line) this modification resulted in a savings of 100HP savings and has significantly reduced the risk of tub fires. Lubrication isessential in this machine. Chain idlers and slug bars must be lubricated everyten hours of operation. Tub bearings must be lubricated every 40 hours ofoperation. Grinding motor, hydraulic motor and tub drive gearbox must be checkedand lubricated annually. Hammers and screens must be checked periodically basedon use to determine amount of wear and overall condition. Hammers are replacedas needed, normally in sets because of the need to maintain balance at highspeeds. Screen can be re-sharpened and re-used. It is important to ensure thehydraulic system fittings and hoses are in good condition and without leaks.Operating manuals, spare parts and training are available from Dura Tech, P.O.Box 1940, Jamestown, North Dakota 58402-1940.

Solar heating and storage tank system for soy wax, comprised of thefollowing; an 8000 gallon plumbed storage tank, 2 eight foot by four foothi-efficiency solar panels, 2 80 gallons hot water storage tanks, a Novantemperature control with optimizer and a taco bronze 180 watt circulating motor.Purchase price for a system, $16,000. Soy wax is an integral element of the firlog product. It must be stored at a temperature of above 105 degrees. The solarcollection and heating system is designed to effectively and efficientlymaintain the soy wax temperature without the continuous and costly consumptionof commercial electricity. The solar collectors are sized so that hot watercirculating through the wax tank keeps the soy molten and available forinjection to the system. This ater also circulates through two electricallypowered hot water heaters that can maintain this temperature on cloudy days orduring the evening hours. The system is relatively maintenance free but requiresmonitoring of water and wax levels as well as a daily check for leaks. The waxinjection nozzle must be checked several times each day for blockage or residualwax buildup. Setting up this apparatus is complex; hiring an outside contractoris necessary. For LBI, they hired Waldemar Baumgart of Lyons, CO, who charged$8064 for two weeks of engineering to set up the system.

Soco System, comprised of the following; a PI-1212 palletizer with autoloading pallet magazine, a T-10 automatic carton erector, an automatic cartonsealer, a linear and curved conveying system, and a motorized product alignmenttable. Purchase price for a used system, $83,076. The Soco System automaticcarton assembly, carton sealing and palletizing equipment are designed forsafety and ease of operation. This equipment will erect the cartons and, onceloaded with the product, will then automatically seal and palletize the cartons.Designed in Sweden, these systems are in use in a variety of manufacturingapplications around the world. Once the system is established, and personnelfully trained, this system is very safe and reliable to operate. A primarymaintenance requirement for this system is to provide clean air for the controlelectronic cabinet. This is accomplished by the use of an air filter built intothe cabinet. The filter should be checked once per week for any obstructions.Several chains are part of the system they move the empty and loaded palletsto their destinations. These chains should be checked once per week for properlubrication. The small electric drive motors utilize sealed bearings and shouldbe examined for any severe temperature fluctuations every six months. On siteservice, parts and technical support are available from Soco Systems, 1931Macarthur Road, Waukesha, Wisconsin 53188-5702.

Allpac A94-176 Super Seven automatic wrapping machine. Purchased used for aprice of $74,400, it is essentially a machine of photocells and advanced relaysto perform precision packing. The Allpac Super Seven wrapping machine is ageneral purpose machine built for fast packing of fire logs, ranging in sizefrom 2.5 to 5 pounds in weight. This machine is capable of packaging up to 70logs per minute at peak performance. Allpac, Inc., is an industry leader in themanufacturer of high-end packaging equipment. Intensive engineering and highstandards in manufacturing practices have produced a machine that requires verylittle maintenance. Annually, the gear systems should be checked for properlubrication and electronic eyes should be kept clear of obstructions. Shouldservice or parts ever be required, Allpac has available technical assistance.They can be reached at Allpac, Inc., 2301 Farrington, Dallas, TX 75207.

LBI implemented an aggressive training program to ensure their employeescould safely and efficiently operate the aforementioned equipment. Projectdirector Mike Casebier traveled extensively and received all initial training.Mike then, in turn, trained others at the LBI manufacturing plant in Winslow,AZ. For example, Mike received one week of training on two systems, the Socosystem and the Allpac Super Seven. He then conducted training for the subsequentfive weeks, for three employees. Total cost of this training package was $8,176.As another example, training on the solar heating and storage tank system forsoy wax required three days and cost $4579. Accessory training was also phasedinto the program. LBI spent $2860 training employees on such things as fireextinguishers, forklift operation and safety, safety devices and machine safety.This safety training was very thorough. For example, machine safeguardingincluded some of the following: Hazard identification, types of hazards,controlling hazards, types of guards, types of devices, inspections, clothingand jewelry restrictions, lockout procedures, preventive maintenance andenforcement. This latter training was conducted by Personnel Safety Enterprises,Inc., 5400 North Dodge, Flagstaff, AZ 86004, phone number 520/526-3130.