PROJECT OVERVIEW

INTERNATIONAL WOOD INDUSTRIES, INC. &
BONFIELD FOREST PRODUCTS PROFILES

state-of-the-art Facility producing high quality products in a highly efficient, environmentally friendly manner.

Armed with a solid business plan, including confirmed wood fibre commitments, identified product customers and the funding necessary to build AND operate this state of the art facility, we are working diligently, and tirelessly to obtain the numerous government permits required which will allow us to begin construction and to become the region’s newest and most respected employer!
International Wood Industries, Inc (IWI) is a development company specializing in the forest products industry.  The company was incorporated in 2001 in Ontario, Canada. In 2016, the company saw an opportunity to develop a new forest products facility in an area of Ontario that was under-serviced. Meaning our research told us there was a confirmed availability of wood fibre to feed a new mill, harvesters willing to harvest the available fibre, an available and ready workforce, and that there was a void of mills within this immediate region, one with a long forest sector history. After reaching out to potential fibre suppliers who formally confirmed their willingness AND ability to provide us with the fibre we needed, IWI decided to proceed with development of a new forest products manufacturing facility.
During 2017-18, the concept of the manufacturing facility was developed. This facility’s concept is somewhat unique in Ontario. Because of the fibre being formally offered to IWI consists of both hardwoods and softwoods, it made sense to design the facility to process both hardwoods and softwoods. Production would be designed to process all available wood species all the way to finished products. Secondary production is where wood products see significant increases in value. This was our goal to achieve when we designed the facility. The diversity of fibre being made available to us would become our business model’s strength.
In looking at production rates, we decided to incorporate as our centrepiece of the sawmill a primary breakdown unit known as a “Hewsaw”.  This is Finnish equipment and there are Hewsaws that operate throughout the world. Over the years, a number of sawmill facilities in New Brunswick and Quebec upgraded to Hewsaw units.  We visited many of these facilities, in Canada and abroad. The advantage of the Hewsaw system is speed of production and the ability to process roundwood down to 3” tops. The Hewsaw can process a log in a single pass and at speeds up to 600 fpm. (2.5 seconds per log)  A log goes in and lumber, chips and sawdust comes out.  And the ability to process logs down to 3” tops gives this sawmill a real advantage. This enables this sawmill to make more efficient use of the forest. Traditional sawmills would not accept round wood with top diameters less than 8 inches. But this mill can and will accept small wood – a big advantage in first securing the wood fibre and then converting that wood fibre to valuable wood product. One other consideration regarding Hewsaws is the increased safety of operation over other systems.
According to North America Hewsaw representatives, in Ontario there are four Hewsaws in operation. This Hewsaw will be the fifth.  Some interesting features of our Hewsaw is that it will be the largest Hewsaw in Ontario able to process logs up to 21 inches in diameter and further downstream some secondary Hewsaw processing. This will be the first Hewsaw in Canada with this configuration and the sixth in the world.

In order to bring the project to fruition, many things needed to be accomplished. First, a suitable site needed to be secured. The general area where to locate the facility had been established. IWI then needed to find actual land parcels that would meet its needs. The main requirements were:

  • 200 ACRES IN SIZE
  • ADJACENT TO A MAJOR HIGHWAY
  • ACCESS TO A RAIL LINE
  • AVAILABILITY OF HIGH VOLTAGE POWER.

IWI was able to secure three contiguous parcels of land that met these requirements. The land was secured through Agreements of Purchase and Sale conditional on a number of items such as successfully rezoning the property for industrial usage, conducting site investigations including an Environmental Assessment, Soils Tests, Species at Risk, a Traffic Impact Study, to name a FEW. These items have all been completed and in the Spring of 2019, IWI completed the final designs of the process, the site works and buildings.

A general description of the entire mill will reveal the green nature of this project. The mill is being designed with some European technology and with the concept of “0” waste.
The preliminary, original site plan shown below showcases the location of the property and its proximity to the highway and the railway. By installing a rail siding, in addition to traditional truck delivery, the railway will provide us with an opportunity to receive logs by rail and to ship out chips, containers and lumber packs to our customers within and outside of Canada. Our Sales and Marketing Director’s work in 2018-19 confirms the demand for and interest in our products.

The preliminary master site development plan: Main entry to the plant will be off of Trout Pond Road. Trucks coming into the yard will be weighed, drop off their loads onto the log sorter decks. There are two decks as infeed for the log sorter. One deck will take tree length where the tree length logs will be slashed to length and then fed into a conveyor to be scanned and sorted.  The second deck will take “cut to length” logs and fed into a conveyor to be scanned and sorted. Each log will be sorted into bins by species and diameter. The sorts from the bins will then be taken by a Front end loader and stockpiled with the same species and diameter.

The next step is the infeeding into the sawmill.   It is planned to do batch cutting which means a particular pattern is chosen based on product demand and then a specific log diameter and species is selected to be processed. Batch cutting allows shorter distances between logs as they are fed through the Hewsaw and the result is greater production is achieved per shift. As logs are placed on the infeed deck to the sawmill, the logs are fed through a debarker.  All the bark collected will be used by a Bark Burner/Boiler system to produce heat for the buildings as well as for the dry kilns.

There will be a total of three debarkers for the debarking of logs and thus gives a lot of flexibility in accomplishing this operation.
In addition to the Hewsaw sawline, there will be additional primary breakdown lines that will cut wood in the more traditional way. With these lines, the sawyer can cut the larger diameter logs and can cut for grade. Cutting for grade will yield much higher quality wood which commands higher pricing. The additional sawlines will cut mostly hardwoods and pine products.
The residue from the sawing process (chips and sawdust) will be collected and sorted. The mill has in its design, a pellet mill, which will make pellets, bag the pellets and sell to retailers. The mill has the option to make additional pellets from its chips or to sell the chips to corporate clients who we have been in communication with. This decision will be made  based on further economic evaluation closer to production time.
In summary, Bonfield Forest Products will essentially be a “zero waste”, environmentally sound facility with all its residues used for other purposes. (heat production from bark and pellet production from chips and sawdust).
All lumber produced from all sawlines will be fed into one of three sorting lines with two lines having trim lines and grading stations and numerous bins and one manual green line utilizing manual pulls for sorting.
Two of the green sorters will have sticker-stackers for preparing the packs for the next stage – the dry kilns.
The mill plans to have a number of continuous feed dry kilns for the drying of production. Packs will be stockpiled under cover in preparation for the drying process. After drying, most packs will proceed to the planing mill.
In addition to the dry kilns, the mill will have some vacuum dry kilns.  This is German technology that can be utilized to dry, along other things, heavy timbers, with a dramatically reduced drying time.
The planer mill will have three different processing lines. The first line will be a traditional planing line that will produce finished dimensional lumber. These products will then be packaged and tagged for shipment.
The second line will be a planer/moulder line that will be used for producing a number of different products and profiles.  One of the main products that the mill is planning to produce will be solid hardwood flooring.
The third line will be a CNC machine which will produce, upon other things, log home packages that can be shipped worldwide.
In summary, this mill will be state-of-the-art producing high quality products and in a very efficient manner.
Final design, our construction and operational plan will be shared publicly once MNRF approves our facility license. We expect this to be  Summer 2019.