Testing Novel Wood Flaker for the First Time in North America
This project was funded through ERA’s Food, Farming and Forestry call and tested a novel method of making wood flakes using a unique combination of equipment. While the project was ultimately terminated, this equipment combination is the first attempted use in North America and supports further innovative methods of enhancing carbon sequestration in Alberta’s forestry sector.
Instead of the traditional wood flakers, this system uses a three-part process: a “roundup” machine first removes bark and irregularities from logs, a spindleless lathe peels thin layers from the logs and a clipper chops the veneer into flakes. This method uses far less energy—about 34 per cent of what conventional flakers use—and creates wood panels that store more carbon and potentially replace imports or non-renewable materials in buildings.
Saving Time and Funds with a Pilot Plant
During the project, West Fraser and its partners set up a small pilot plant using a spindleless lathe system to test how well it could make wood flakes from Alberta’s surplus poplar. The funding relationship was terminated shortly after testing began. Despite this, the project yielded important lessons for future projects. One of the biggest lessons learned was the value of building a pilot plant before investing in full-scale production. West Fraser built a pilot plant that cost less than 1 per cent of a full plant, saving significant capital and helping identify issues early. The team also learned the importance of ensuring foreign-made equipment meets Canadian safety standards before it arrives. While the electrical systems for the technology were certified in advance, the mechanical safety parts were not, which caused delays and extra costs. Fixing those safety issues after the equipment was shipped to Canada cost over $50,000 and would have been cheaper and faster if handled beforehand. These experiences showed the importance of careful planning and setting clear requirements when working with international suppliers.
What’s next?
Since the funding relationship was terminated in 2024, ERA is not aware of any further work by West Fraser to develop this technology.