Due to regulations in Europe and global companies looking to standardize pallet sizes across markets, block pallets are growing for export applications from North America. A relatively new entrant to the U.S. and Canadian markets when it comes to supplying composite blocks is Archimbaud Sawmill Group, headquartered in France.
Over the last ten years, Archimbaud has become one of the largest pallet manufacturers in France, producing almost ten million pallets across multiple plants. In addition, Archimbaud opened in the spring of 2020, the first French manufacturing site for 100% recycled wood pallet blocks. The plant uses a full composite block production system designed and built by IMAL-PAL Group, known for producing some of the best industrial block production equipment in the world. This investment of 22 million Euros had developed a state-of-the-art block production facility offering consistent-quality blocks, produced efficiently and ready to ship to North America, Europe and the Middle East. A very extensive process is used to produce these blocks. Material is crushed to a granulometry of less than 6 mm, dried and glued with a resin-paraffin mix. The resin-paraffin mixture is then dispensed on extrusion lines and cut to the required size. The entire line is computer-controlled and fully automated.
Everything Archimbaud does is designed around sustainability and providing cost-effective products to customers. Jean-Pascal Archimbaud, the president of the Archimbaud Group, said, “I am heir to a family tradition that taught me to transform natural resources into useful (often indispensable) assets for the society in which we evolve. I have chosen to guide the development of the Archimbaud sawmill according to this founding value: the usefulness of our products, our growth, our waste. This permanent search for the ‘best service’ has enabled the sawmill to become a solid group renowned for its commitment to industrial ecology.”
Archimbaud Produces Sustainable Blocks
Archimbaud’s goal is to produce, “The most sustainable block on the market.” And the company has a strong track record to show its green credentials. All blocks are produced from 100% recycled wood fiber. Archimbaud has branded its blocks with the Archiblock® trade name. Why is finding the right block so important?
For starters, the major certification standards used in Europe (EPAL) and (EUR) both require composite blocks to ensure consistency of quality and size. Second, the environmental footprint of the block construction travels with that block wherever it goes. According to Archimbaud, the composite block is an important part of the environmental impact of pallet production, representing up to 30% of the volume of a pallet. If you get a greener block, those ecological benefits can be applied to sustainability targets for the North American producer as well as its customers.
With an annual production capacity of 130 million cubes, Archiblock® can recover up to 100,000 tons of material destined for disposal. All recycled wood used in Archiblock® production is sourced within a maximum radius of 100 km from the production site located in Mauzé-sur-le-Mignon. The ideal location along the Atlantic Ocean means that shipments can be easily and quickly shipped to foreign markets. Archimbaud has ten different molds and can change heights and thicknesses produced in its plant.
Fabien Guais, a sales representative with Archimbaud, noted that the geographic location allows Archimbaud to ship products faster than many competitors. He said, “The manufacturing process and continuous quality controls guarantee that each composite block has perfect dimensional stability. The blocks are resistant to staining, fungi and mold. They also have excellent resistance to nail extraction.”
Looking at the energy efficiency of the Archiblock® production process, it saves 75% of the energy needed to dry the material of a traditional chipboard composite block, according to Archimbaud. Due to the consistency of the wood fiber, the drying time at the end of production is reduced by 30%. Also, the particularly low moisture content of Archiblocks allows for a threefold increase in productivity during hot stamping of pallet marks.
Jean-Pascal said, “We built the Archiblock® plant in Feb 2020. We decided to do a greenfield plant and destroy the old facility on this site. It gives us plenty of space to grow, add more lines and storage. About 50% of the material used to produce Archiblock® comes from our own facilities.”
Quality Control Is Critical for Block Performance
Archimbaud has an in-house testing department that conducts regular spot checks to ensure consistency throughout the manufacturing process. Fabien commented, “Blocks are regularly tested for dimensional stability and consistency as well as resistance to nail pullouts.” This laboratory has equipment designed by IMAL-PAL Group to monitor every part of the process from the initial material to the final products to the condition of the adhesive used.
Jean-Pascal explained, “We use lines from IMAL-PAL. These lines are ideal for our needs and are used by other suppliers in the industry in Europe.”
The company offers two versions of its pallet blocks, Archiblock® and Archiblock+®. Archiblock+ features a resin-based manufacturing process and has water-repellent properties. It is recommended for returnable pallets, such as EPAL and UIC pallets. The blocks are available in a variety of dimensions.
Fabien stated, “Archiblocks are designed and formulated to be naturally resistant to staining, fungi and mold, which makes the assembled pallet more resistant to aging.” The consistency of the block allows for 100% secure nailing when assembling a pallet while eliminating risks of splintering or flashing common with solid wood blocks.
Green Energy for the Future
During my visit to the Archiblock plant, the level of precision and forethought to every detail of the production process was impressive. The team’s commitment to strong environmental practices was evident too. Many of the Archimbaud facilities use biomass energy and/or solar panels as part of their attempt to reach energy neutrality when it comes to the environmental impact of energy consumption. With an annual production of 29.1 GW for a consumption of 38.6 GW, the group produces 75% of the energy it consumes. The electrical production is entirely injected into the general network and covers the annual consumption needs of approximately 6,000 households. In addition to the thermal energy produced by the company’s cogeneration plant, 13 biomass boilers provide all the group’s sites with a thermal capacity of 56 MW. This energy covers all the needs of industrial production: sawdust drying and pallet dryers. The heat produced is entirely dedicated to the industrial needs of the Archimbaud group.
Jean-Pascal said, “Beyond our traditional cogeneration plants, we are working on a system that produces bio-hydrogen from wood pellets.” When I visited last year, the facility was still in the developmental stage, but the technology shows promise for the future. It could become another good use for wood fiber and pellets if hydrogen-based vehicles or energy systems take off in Europe.
Government funds have been used to help develop some of these new projects, including the Archiblock® production plant.
Archimbaud Pallet and Lumber Operations
While the company’s roots are in the sawmill industry, over the last 10 years, its pallet production capability has grown significantly. From its twelve pallet plants, Archimbaud produces about nine million pallets per year. Nine of the facilities are in France, three abroad – one in Brazil, one in Abu Dhabi and one in Italy. Some of the facilities also produce lumber for various markets. Fabien said, “The Brazil facility was developed originally to ship wood to Abu Dhabi for pallet manufacturing. And now that facility is providing lumber for Mexican and American markets.” Archimbaud actively sells pine pallet lumber into the U.S. market.
Supported by lumber produced at the Mignon facility, the Archimbaud group’s pallet production benefits from 11 high-speed nailing lines. I visited the Mignon facility and was impressed with its log throughput. The company’s pallet operations require about 450,000 cubic meters per year. About half of its lumber production for the French facilities comes from the Mignon plant run by eight workers.
Augustin Renard, director of the Mignon plant, said, “Archimbaud has invested in the facility, growing its workforce and boosting production. The company built a new plant outside of town a few years ago and invested in new CAPE lines.” He added, “Our waste from the sawmill goes to Archimbaud for pellet production. We also sell bark for landscape material.”
This facility runs two CAPE lines and two TreeLine machines. Today, the plant employs around 80 people for its sawmilling, nailing, drying and admin functions. The Mignon plant produces about 1,800,000 pallets per year. Archimbaud uses solely thinned wood and prioritizes local species, sourced close to the manufacturing sites. Common species utilized by Archimbaud include maritime pine, Douglas fir, spruce, fir, larch or poplar.
The Mignon plant processes primarily softwood material through a Sawquip industrial bandmill feeding into Storti saws for further processing. Archimbaud manufactures a wide variety of high-quality pallets, including EPAL, CP (chemical), VMF (wine and liquid transport), and GALIA (automotive) pallets. According to the company, the Archimbaud Group is the French leader in the manufacture of 2-way entry herringbone pallets.
Jean Pascal noted the extensive covered storage capacity of the company. He said, “Our storage capacity (200,000 m2 – including 40,000 m2 under cover) coupled with our network of transport partners enables us to manage your stock of pallets and to ensure your supply throughout the year.”
The Mignon plant is part of Archimbaud’s aggressive growth strategy through strategic acquisitions. The previous company was more than 40 years old, created by two brothers who sold off the business when they were ready to retire. Fabien commented, “Jean Pascal shared their values, and Archimbaud modernized the company and facility and kept all the employees. So, it was a big change that benefited all the workers.”
In addition to the Mignon plant, the company has upgraded its nailing production equipment at other French locations. Jean-Pascal said, “We are investing in the future and improving the capacity of existing lines.”
Diverse Product Mix and Customer Base
Archimbaud has grown by offering a wide variety of products, from lumber and composite blocks to pellets and wood energy generation to pallets and pallet kits.
Fabien admitted, “We strive to have a diverse customer base. About 25% of our pallets are going for a renting company. Between 20 and 25% is for the building/construction sector. The rest is divided for food, pharmaceuticals, automotive and chemical and industrial applications.”
Since 1984, the Archimbaud Group has been structured and developed around one main activity: sawing local wood for the manufacture of wooden pallets. Over the years, it has added new products aimed at using this wood material in environmentally responsible ways. Since 2007, it has been transforming wood chips, sawdust and bark into wood pellets for heating applications.
The Archimbaud family business, still anchored in the Deux-Sèvres and Landes regions, has become a leading sawmill as well as pallet company in France. With the acquisition of the company in Mignon in 2011 and that of Francepal at the end of 2020, the group has also established itself as one of the very first French manufacturers of pallets made exclusively from French wood.
Fabien retold Archimbaud’s pallet success story. He said, “Jean-Pascal started in the sawmill of his parents and grandparents when he was young. The sawmill cut wood for pallet manufacturers. When he bought the company, he decided to start making some pallets. Over the years, he bought a number of pallet companies and has grown from producing no pallets ten years ago to making more than 9 million pallets per year.”
As the owner, Jean-Pascal was recently thinking about the future of the company, and he decided to transfer ownership to a foundation run by key employees. This will help ensure the future viability of the company. Jean-Pascal is the president of the foundation called “Foundation for the Wood and the Human.”
If you are looking for a composite block supplier and you want a company with a strong environmental record and focus, Archimbaud is a good fit. Its new facility has plenty of room for growth. For more information, visit https://www.groupe-archimbaud.com/en/pallet-composite-blocks/.
