Fed Co-op and Ainsworth plywood plants survive
recession by concentrating on quality vs. quantity

In the volatile world of plywood
prices, two unionized operations in
IWA-CANADA Local 1-417’s (Kam-
loops) jurisdiction have been able to
prosper. Both operations; Ainsworth’s
Savona plywood division, and
Federated Co-op’s Canoe B.C. mill
have kept their heads well above the
water line because they have been
producing high value added plywood
products.

“These plants, although there have
been some small downturns here and
there, have been some of our steadier
operations,” says Kevin Kelly, presi-
dent of Local 1-417. “They have both
been able to penetrate some very
important markets with specialty
products. This has kept our members
on the job for the most part.”

Ainsworth has been specializing in
high-grade, high strength panel prod-
ucts which are finished with overlays.
Meanwhile Federated Co-op has been
pumping out some of the best fir and

spruce plywood that is offered by
Canadian producers.

Both plants have something in com-
mon. They employ more people per
unit production than most modern
sawmills. The result is that there is
more hands-on grading of the produc-
tion which has resulted in higher qual-
ity plywoods.

The Ainsworth plant situated in
Savona, about 40 km southwest of
Kamloops, produces a number of ply-
wood products of which their Medium
Density overlay (MDO) and High

Density overlay (HDO) plywood are
the most popular.

The mill mostly utilizes fir to pro-
duce the panels which are covered in
resin impregnated overlays, which
leave hard and durable finishes. Most
of the panels are sold to customers in

¢ At Ainsworth’s Savona plant patcher Gurpal Singh Litt carefully goes over
veneer.

the construction industry where they
are used to pour concrete.

The overlay gives the user a teflon-
like surface which separates from
dried concrete easier. Thus the ply-
wood forms can be used repeatedly.

In the old days, plywood sheeting
was used with an oil application.
These type of forms only lasted for 2-3
applications.

The MDO overlay concrete form is
good for 20-40 pours, while the HDO
version can last up to 200 pours.

Quality control specialist Gordon
White says the MDO107, is the mill’s
bread and butter.

Sizes can range from 2’x8’ to 3’x8’
to 4’x8’ and slightly oversize panels.

The mill puts 2 people (a grader
operator and a grading assistant) to
work grading the panel. Whereas most
mills have one grader, each grader at
Ainsworth is responsible for inspect-
ing one end, one edge, and one face.

The MDO products consist of kraft
paper overlay that is impregnated
with a resin and dye. It is pressed on
to the plywood with a substrate glue
line that bonds to the wood surface.
The overlay is translucent - so light
gets through to show the customers
exactly what they are getting under-
neath.

The company’s “A” mill puts about
40-42 IWA members to work per shift.
Meanwhile an old “B” mill provides 15
jobs per shift.

The HDO product is a very labour
intensive operation. Ainsworth uses 4
people on the layup line in addition to
the core feeder.

Mr. White says most plywood plants
have more automated systems, but
with the type of panel Ainsworth
wants it is better to have a hands on
approach.

e At Federated Co-op’s plant in Canoe, B.C. local 1-417 member David Weil
feeds core on layup line.

“The more hands that handle and
touch the veneer, the better we are in
the long run,” said White. “Automa-
tion removes people but it also takes
away quality control.”

Most of the HDO goes south to the
United States. The company also sells
in Canada and has begun to make
some inroads into Japanese markets.
The Japanese are learning about the
advantages of using softwood ply-
woods as their sources for Asian hard-
wood plywoods have been dropping
off.

All concrete form and overlay pan-
els are made of 100% Douglas fir from
the B.C. interior. Fir gives the prod-
ucts their maximum strength to value.

The company also produces tradi-
tional %” spruce sheathing sold in
Canada and now in Scotland and
Japan. To ensure that the sheathing is
of top quality the face stock is fully
patched and upgraded.

In other product lines the mill pro-
duces a medium density plywood
used for signs, siding and shelving and
also makes a reflective surface prod-
uct used for highway signs.

Ainsworth also does a “decking
panel” for flat deck service trailers
which is a non-skid panel. A wire
mesh- green is applied during the hot
press process between the cold plate
and the panel.

The company makes core for K2
skis which are manufactured in the
US. It dries packages and ship’s cus-
tom cut 4” Spruce used for downhill
ski assembly.

One hundred and twenty workers
are on the IWA seniority list.

Bernie Vanderwal, the union’s plant
chairman says that the recession
brought some down time and a short-
ened work week.

A UIC work sharing program was
put into place a couple of times. It
didn’t go too good the second time
around. Brother Vanderwal says that
most of the workers “would rather see
a total shutdown and collect UI for a
period of time. . . “ rather than go
back to work sharing.

‘The workers had too many prob-
lems waiting for their UIC cheques to
come in.

Another issue at hand is that of
weekend clean up which the company
is currently paying to casuals at
straight rates. The union has taken the
case before the Interior Forest Labour
Relations Association.

At Federated Coop’s specialty ply-
wood plant in Canoe, about 120 km.
east of Kamloops 140 IWA members
are employed making high quality
spruce and fir plywood.

’ Both companies
believe labour inten-
sive production
inspection methods
will ensure quality

The plant holds the distinction of
being the first one in the province to
receive the JAS stamp of approval
which enables it to directly ship to
Japan. It received the approval in 1987
from the Council of Forest Industries.

Over 18% of its total production
goes to Japan, 5% to Europe and the
rest is sold domestically.

The company is operating a new
tongue and groove machine which fits
Japanese market needs. The tongue
and groove machine also produces
COFT's patented floor products.

The mill can produce over 400,000
sq. feet per day on aX” basis. It’s lathe
can peel a maximum of 600 lineal feet
per minute.

From the lathe the veneer goes to
an automatic sort system where it is
separated by moisture prior to stack-
ing. Fish tail and random pieces are
off-beared manually.

Continued on page thirteen

12/LUMBERWORKER/SEPTEMBER, 1993