At The Sawmill
Bereco are unique in that we have our own dedicated sawmill supplying our factory with sawn, kiln dried and finger jointed laminated sections for our wooden windows and doors.
Located in a small community village where about 900 people both live and work, the sawmills location in the center of the Tuchola forest is not only close to our production facility keeping down transit costs but the reduced distance the timber travels from sawmill to factory reduces our overall carbon footprint. Previously a mill for dried sawn timber and furniture production the owners closed the operation and with it many people in the isolated town found themselves out of work; with adoption of the sawmill in 2006, 50 people from the locality kept their jobs and with the introduction of the glued laminated timber line a further 10 jobs were created. The mill continues to employ 60 people to this day supporting the local economy.
How it works?
From the Forest to the Mill Yard
Harvested FSC 100% timber is delivered from the nearby forest to the mill yard.
Logs are sorted by heartwood content, size and diameter ready for processing through the mill.
De-Barking & Sawn Timber Production
Bark is removed from the cut and sorted logs and the correct width of boards are cut for each different window and door style we make.
Stacking & Kiln Drying
Sawn timber is stacked in the yard ready for the kilns. Our sawmill operation has five kilns for the drying of the timber. Each kiln dries the timber down to a moisture content of between just 12% and 15% the optimum moisture level for stability; a necessity in structural timbers used for construction.
Planing of Timber
Once dried the timber enters the laminated timber line or Glulam line as they are often called. Here the timber is planed first of all to remove all rough edges.
Once planed; our trained timber operatives mark out sections on the wood where defects such as knots and shakes are apparent using an orange highlighter; the machine then x-rays the surface of the planed timber looking for these highlighted lines and makes a cut where the line is creating defect free timber sections.
Now the knots and shakes have been eliminated the sections that remain are finger jointed; finger jointing is recognised as the most stable method of jointing together timber into lengths creating a strengthened bond between two sections of timber that is by many considered stronger than the timber itself as a solid piece.
Glueing & Laminating
The finger jointed sections are in turn glued and closed together piece by piece under the pressure of a machine creating a perfect flush seam. Sections are then glued and laminated together for stability in 3 layers the grain of the central layer running in the opposing direction of the outer layers.
Quality Control & Packaging for Production
Each completed finger jointed and laminated timber section is then inspected for quality removing any not to standard timbers. Finally the sections are packaged; labelled and ready to be shipped into the factory for production to begin.
Why do we have a sawmill?
The key driver for the adoption of the sawmill into our supply chain was for improved control of the timber section sizes. It is the norm for wooden window and door suppliers to use ready made up sections of laminated timber from sawmills to standard section sizes to make their windows and doors. At Bereco we are a little bit different and well the norm is just not good enough. Our dedicated sawmill enables us to take a blue sky approach to designing all our own timber windows and doors starting with exclusive sections sizes that give robust construction, stability and superior quality proven by testing they perform to the highest security and performance standards.
In addition 2006 saw an unprecedented demand and an acute shortage of redwood pine laminated sections. With 90% of the timber used in construction in the UK being redwood; supply problems caused drastically extended lead times of wood manufactured products; which for many caused not only a major inconvenience but severe delays on site. It was with this that Bereco actively sought to reduce this risk going forward.
Having our sawmill for us simply means we always have superior timber stock available in the right section sizes, designed for homes in the UK that meet with the exceptional quality standards we impose on ourselves and those our customers have come to expect from Bereco.
Fully certified laminated timber.
The redwood raw material is FSC 100% from FSC certified forests as well as the sawmill plant itself being a certified manufacturer and supplier of laminated timber.
Innovative solutions for waste management.
Wood waste generated in the production process of our timber windows and doors is transported by a silo system to a concrete silo with a capacity of about 500 m3, from where it is automatically collected by the fuel supply system to the boiler. Out of the heating season, surplus wood waste is briquetted for use in the furnaces and fireplaces of the local village.
Nothing goes to waste. All our timber windows and doors are delivered on FSC 100% timber pallets made from the wood that comes from our forest and the offcuts from the sawmill. These pallets are then collected post-delivery where possible and reused for future customer deliveries extending their service life before eventual recycling is needed.