First, I think it is wise for a business to start small and grow larger instead of the other way around. I believe this is one of the best ways to have a larger business that is successful. This is exactly how Cooks Saw has grown. Start with small things and get it running smooth and then double the operation, then triple it, ect. I know 'small' is a relative term so as I explain you will get an idea of what I see as a good starting point for an operation.
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Using a Portable Sawmill, Here is How to Cut Cross Ties with a
Target Goal of 400 Cross Ties Per Day:
Up front we know that one portable sawmill using 1-1/2 band saw blades will not cut 400 cross ties per day. But let us concentrate on what one sawmill can do. An AC-36 portable sawmill with a 51 hp diesel (or a 30 hp electric) will cut a sweet gum tie in 4.5 minutes. That is the complete time it takes from when the log hits the loader to the point that the sawn cross tie is being unloaded from the sawmill. Of course the sawyer needs to only concentrate on sawing while someone else is doing the off loading and stacking.
In a typical operation there are 8 hours a day in which to produce cross ties. That's a total of 480 minutes in those 8 hours and with each cross tie being produced in 4.5 minutes there is an opportunity to produce 106 per day. But we can't be at perfection all day so the idea is to realize how important every minute is and how important every 4.5 minutes are.
Every time you are sawing for 4.5 minutes you should be producing a cross tie.
I know that all logs are not the same and that some logs have more side lumber than others. We know that the more side lumber you cut, the more time it takes to produce the cross tie. I timed myself with a Red Gum log which is a fairly softer wood compared to a Hickory or White Oak log.
However I can saw a Red Gum tie a little faster than 4.5 minutes when there is no side lumber and just 4 slab cuts. I can shave off 1 minute and saw that in 3.5 minutes. But If it were a Red Oak with 6 extra side boards It will take an extra minute at 5.5 minutes. These things have to be averaged to calculate accurate production.
Also to reach these speeds the portable sawmill and the band saw blades will have to work correctly. The Super Sharp Magnum blade 1-5/8 x 055 x 1" is the only way to go to get these kind of production speeds. Another strong band saw blade is the Super Sharp 1-1/2 x 050 x 1".
Horsepower will determine which band saw blade is the right choice. You must use the saw blade that will use all of your available horsepower. Of course saw mill alignment is a must. Not just close alignment, but perfect alignment is required. When a portable sawmill is perfectly aligned it will saw straight through any knot that comes in its path (many people think it is acceptable to rise at knots, I say that it is unacceptable). When band saw blades are not cutting straight there is a physical reason and it can be overcome.
You must also consider that there will be break down times. When logs are being handled and machinery is moving, things will happen. Be determined to fix it quick. Simply fussing and complaining only makes for more time loss. Grabbing the tool and making the repair should be your focus.
When you have to call a sawmill manufacturer to get help with a problem, be focused on the problem. Don't tell the tech person every problem you've ever had with the sawmill - this leads to confusion. Deal with the immediate issue at hand; this leads to quicker solutions.
In addition, you must have a decent welder if you intend to saw for production. There will be a time that a quick weld will save the day. There will be times that you can weld something simple and make things run smooth. You've heard the saying... 'it takes money to make money' well it takes a welder on hand to run a production sawmill operation.
When you deal with machinery that takes a beating like a portable sawmill, things gets broken. But with a saw mill you don't just carry it down to the local John Deere dealership like you do a tractor; you learn to fix it yourself.
With one sawmill running full production the next stage is to add one more sawmill and one man. It is easier to run the second sawmill to full production than the first and you will double production with the second mill.
When this is accomplished and you want to double again you add two more sawmills. At this point you will have four sawmills that should each produce 100 ties per day. I think it is best to put the sawyers on an incentive to reach the 100 ties per sawmill.
Not every person can organize himself to reach these goals, but find the people who can. Also understand that if the logs are larger, the sawmills must cut more side lumber and this reduces the number of ties daily.
Now that you can see that 4 sawmills produce 4 times the lumber let me describe a setup that is efficient.
With the drag back features on the sawmill, set a green chain (drag chain) to take lumber away form the sawmills. Set two sawmills on one side of the chain and two on the other side. Offset the mills so the ties / lumber will not jam into the other saw mill. The chain will carry the lumber down to the edger, lumber stacks, and the tie stack stations.
From this point you can adapt with things that make handling more efficient. With this type of setup you can be the most productive as possible. As you invision this, note that the edger can handle 4 sawmills with no problem. You may have to increase men to stack based on production. With good planning 400 ties per day will be a daily flow.
To end, I would like to explain why I like to 'grow' to this setup. I have seen people set up huge portable sawmill operations and go broke before they get started good. With this setup you get familiar with the sawmill and your markets. Then you grow larger one step at the time, one sawmill at the time.
If markets change you can sell off one sawmill at the time. We know how help is, if one worker lays out or is sick then you are running at ¾ production. If one sawmill breaks down, you are running at ¾ production rather than with a single big mill saw where everyone stands around watching you fix the sawmill. It keeps you diversified and able to grow as needed.
You might like to read this special cross tie report from one of the largest cross tie purchasers in the nation. You'll get an idea of what is needed and even give the company a call for more details about how you can sell your ties.
Now you have the information about the market, the operation setup, and even connections where to sell the ties. Now it's up to you to make it happen. Give us a call and let us help you get it started.
