Baker Products unveiled its first saw at EXPO Richmond decades ago. So, it is only fitting that Baker Products is launching at EXPO Richmond the first phase of dramatically improving, revamping, and automating many of its flagship machines. A key benefit of these improvements is faster changeover times and improved production efficiency. But that is just the beginning as Baker is focused on a wide variety of automation advances from boosted production to labor savings to making jobs easier on workers to more precise end products to easier maintenance and operation.
Many of these products will be on display at EXPO Richmond, taking place in April 2024 in Doswell, Virginia. See the article on page 50.
Baker Products is a name that most people in the pallet and low-grade lumber industry know. What you may not realize is that all of its models are put through rigorous field evaluations at its own sawmills and pallet facility. Baker’s pallet company, Edward L. Baker Enterprises, has its main sawmill and pallet plant in Ellington, Missouri right next to the manufacturing facility for the Baker equipment.
Brett Baker, vice president of Baker Products, said, “Baker equipment is validated in our own sawmills and pallet operation. We take this real-world experience and use it to improve our products. We are focused on achieving higher production with fewer, happier employees.”
Brett further explained, “An idea can look and sound great on paper or a computer screen. An idea can even come to life in a research and development shop and still look great. But an environment where wooden products are being created will very quickly tell you if something is truly a great idea—that is what is so unique about Baker Products. We use our own equipment every day, which has allowed us to perfect equipment, test equipment, identify weaknesses, and take to market-proven solutions.”
Over the past five years, Baker has more than doubled its capacity thanks to new machinery and locations. The company has added three new nailers in that time as well.
Different Facilities in the Baker Enterprises Lumber Network
Baker Enterprises has been busy adding facilities over the last decade to accommodate its growth, serve expanded markets, optimize shipping logistics, access more timber resources and attract labor from a larger area. The company has opened up a number of various locations to serve as test sites for Baker equipment representing different types of sawmill configurations and objectives.
Brett stated, “Our Ellington sawmill allows us to test large, scalable system layouts. Our Highway 60 location validates our band sawmills and will, in the near future, test a new end-dogging scragg mill. This plant will also be the proving grounds for a radically new manner in which to process pallet cut stock. Our Highway C facility also proves our band sawmill operation. The Grandin sawmill proves a smaller, highly efficient manner in which to process lower grade round wood into marketable cut stock. And finally, the Corning plant validates our in-line layout of a multiple single-man scragg system tied to a can cut-up line. Each plant proves our equipment in unique and specific applications.”
Opening new locations gives the company access to a wider network of potential employees as well as customers. Also, the new locations provide more versatility and moves some production closer to the timber resource. Ed Baker, owner of Baker Enterprises, also owns considerable timber holdings in the region. Ed has jumped at some opportunities as they have become available. Brett added, “We like to be opportunistic when we see a good fit for our expansion plans.”
Over the past several years, Mark Twain National Forest has put a significant amount of timber on the market. This has facilitated Baker Products having access to a reliable and substantial volume of timber.
“In a nutshell, we’ve given ourselves the ability to process almost any kind of log and material that we could possibly get ahold of.”
Baker Enterprises started its first truly satellite location with just a Baker Dominator portable sawmill along Highway C in southern Missouri. This installation is situated near a main logging job where Baker crews cut squares and ties. Squares are sent to Ellington for further processing and ties are sold directly on the market.
Ed Baker then acquired a five-generation sawmill in Corning, Arkansas that had been shut down. All of the previous equipment had been sold off. Baker completely built out the location to house a new Baker scragg line and a Baker cant cutup line with a 5-head model “C” resaw equipped with automated setworks for thickness changes. This move allows Baker Enterprises to source roundwood from Arkansas as well as to sell directly into the Arkansas market. The Corning plant also runs a Viking nailer to produce pallets for that region without having to ship from Ellington.
The next location to come online was a plant along Highway 60 in southern Missouri including a new building to house the equipment. This facility runs two Baker band mills currently processing logs with a Baker End Dogging scragg complete with edger saws slated to be installed this year. Future plans include an automated cut stock operation that will drastically improve the current process with both production and labor savings advantages.
Brett stated, “This facility is going to be our main test center in the future to evaluate equipment for the pallet industry.”
Baker also has a facility in Grandin, Missouri to validate its small sawmill approach using a single man scragg connected to two “A” Model band resaws equipped with turnarounds for one-man operation. The area has a lot of history in the lumber industry. Around 1900 the largest sawmill in the world operated in this town.
A core advantage for Baker Enterprises is its vertical integration from log to finished pallet. Brett noted, “By being vertically integrated, we can control and rely on every component of the supply chain. This approach allows us to decouple from external pressures—land/timber market conditions, logging crews, sawmill operators, etc. All these components dramatically increase Baker Products competitive edge in the pallet world.”
As part of its vertical integration strategy, Baker operates eight mechanized logging machines and one log truck along with contracting two skidder crews and multiple log trucks to support its milling requirements. The flagship sawmill and pallet manufacturing facility in Ellington includes a Baker circle tri-scragg, a Baker cant cut-up line and a Viking Turbo 505 nailing machine.
Redesigns and Enhancements to Popular Models
Baker Products has been working on redesigning some of its popular equipment and improving layout configurations to streamline the processes.
Clay Hedrick, sales manager for Baker Products, commented, “Our real focus with machinery enhancements is efficiency, and that really means labor savings and faster changeovers. We are focused on achieving both without compromising yield.”
Downtime means lost production. Baker’s new enhancements focus on achieving greater production and faster changeover times. Sawmills and resaw operations need to be nimble and have the ability to cut many different kinds and sizes of material.
For example, at the Corning location, Baker has installed a Model C, five-head resaw with a new automatic setwork system. Changeovers that used to take 15 minutes can now be accomplished in five seconds. Hedrick said, “You can basically change the thickness that you are cutting on the fly.” If you made five thickness changes a day that would result in the loss of 250 production hours per year. The new automated setworks allow you to change from cutting various sizes in mere seconds. For example, you can go from 7/16 to 5/8 at the touch of a button.
And another benefit is with a multi-head machine, you have the ability to automatically take heads off-line while still running the others if something goes wrong. Hedrick stated, “Maybe a band breaks or it’s just dulling up on a particular head, the new setworks system enables you to adjust the other heads to compensate while the problem one is idled.” Also, you can continue production and perform the maintenance when a break occurs. Baker is developing these automated setworks for other popular models, such as the AmbiTrim™. This model will be available for live demonstrations at EXPO Richmond. Hedrick explained, “Our new AmbiTrim or multi-trim saw with automated setworks can change length settings at the push of a button.”
The automated setworks is offered as an optional package because some customers don’t make changes that often and don’t need to pay for the added automation. But for those companies that want nimble operations, the new automated setworks are a game changer.
Additional automation advancements include a new feeding system for the AmbiTrim. Hedrick said, “We are working to turn some of these labor and heavy activity positions into machinery operator positions. We’re taking the heavy labor out of it. You’re going to have somebody there monitoring the machine basically, but not somebody that’s having to physically load material or handle material or push and pull material. The result is that employees can work longer and stay fresher.”
Brett further explained, “We just want someone babysitting the machine. One of those operators will be able to handle what three labor positions previously could do. Customers want equipment that improves the job quality, so it is easier to retain workers.”
Baker is also coming out with a new automated pallet board stacker. It will be on display at EXPO Richmond as well. Hedrick said, “This is part of our commitment to reducing labor and transitioning labor-intensive jobs into machine operator positions.” Yet another new machine at the show will be a high-speed board splitter. It is designed to process 2x4s and 2x6s at a rate of up to 400 linear feet per minute. Hedrick explained, “So much of the industry, especially up North and out West, has moved that direction with using only 2x4s and 2x6s.” The Baker board splitter is a circular saw. It will be incorporated into the AmbiTrim demonstration line at EXPO Richmond. This line will also feature a bypass double notcher, and two-head resaw with quick change setworks. Any of these three machines will be able to be run to the new Baker stacking machine.
Second Generation Leadership, Automation of Machinery Plant
Brothers Brett and Beau work together to manage the operations of both businesses. Ed Baker still comes into the office and loves working on new equipment ideas.
Baker Products continues to expand and improve is manufacturing facilities by adding new CNC, laser equipment, and automating wherever possible. The company fabricates all of its frames and parts and plans to incorporate a tube laser into the design process. Controlling all its key design, fabrication and assembling processes enables Baker to tackle custom projects and enhancements to its existing lines.
For example, Baker is building a new tilt hoist to feed a high-speed circle saw splitter. This is a unique way to feed the line and could also be used to feed a Baker Double Notcher. Customers are looking for a way where a forklift driver can drive up with a bundle, set it down and not manually touch anything. Baker is also developing two single-trim saws for a pallet recycler. While this is a very standard piece of equipment, the unique customization that Baker is doing for this client focuses on a unique unscrambler feed design. The idea is to make the machine more user-friendly with less labor. Most of these saws require each board to be manually fed. This design removes that function.
The reality is that Baker already offers a lot of custom parts and add-ons for its machines. Hedrick explained, “So, like a Baker A is a fairly simple machine. But there’s so many different variations. You might be able to order a Baker A in almost 30 different configurations.”
For more information on Baker equipment, call (573) 663-7711, email info@bakerproducts.net, or visit www.bakerproducts.net. Also, come by and see live equipment demonstrations at EXPO Richmond at the outdoor booth number A1.
