
Testing prototype equipment is nothing new to Hodgson's Chipping Ltd. of Truro, NS. The family operation of a father and his four sons tried out the first Peterson Pacific flail chipper to hit the woods back in 1989. Not only was their hands-on experience and feedback incorporated into the design of future Peterson chippers, but the 15-year-old chipper is still working as one of Hodgson's production models.
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Thus it's no surprise that the first Levesque 240 mixed-wood processing head from Quadco is cutting its teeth on one of the Hodgsons' job sites, despite the fact that the crew was more than happy with the processing heads it had been using to that point, a pair of Hornet processors.
"I had a hard time convincing myself to try the Levesque, because we've had such good luck with those Hornets," says Vaughn Hodgson, one of the four brothers and a leading force in the growing company. "But I kept an eye on the prototype as it was being made, and I liked a lot of the ideas that were being built into it. And we've never been afraid of trying something new."
It is also no surprise, then, that the head's early performance seems promising.
Team approach
Hodgson's Chipping is a full-service contracting outfit that does almost all of its harvesting for Kimberly-Clark. The operation was started 40 years ago by McKay Hodgson. One by one the logger's four sons have joined the fray.
For his part, 40-year-old Vaughn started in the operation in 1986, after finishing a heavy-duty mechanics course. Soon after, the operation began mechanizing, starting in 1989 with a rail delimber and that first Peterson chipper. Growth has been steady since, and today the operation employs 40, including the four sons. Vaughn works as mechanic, overseeing the whole operation in an effort to keep everything running smoothly. Surprisingly to some, he says the mix of four brothers and father has served Hodgson Chipping well over the past 15 years.
"It works well. We're each in charge of a different part of the operation, so we know it's all being looked after. My youngest brother, Dale, does the trucking, Roger's in charge of the logging operation in the woods, and Paul looks after the chipping operation. My father is president, and has a say in every aspect of the business."
Operations in the woods are divided into chipping and roundwood harvesting, with all phases handled internally. For chipping, a Tigercat 860 buncher fells for a trio of grapple skidders - a Tigercat 630 and John Deere 648 GIII that feed the newer Peterson chipper bought in 1994, while a Cat 525 feeds the original 1989 Peterson.
Up until a little while ago, the roundwood side consisted of a Tigercat 860 buncher feeding two Hornet processors working at the stump, followed by Rottne and Fabtek forwarders. When it comes to choosing carriers for the processors, the Hodgsons follow a unique strategy. After two years of double-shift bunching, feller bunchers go into the pre-retirement role of processor.
"We put about 4 000 hours on the bunchers a year, so after two years we get a new one, and convert the older one into a processor. It's an easy life for a carrier, and with those hours they do the job no problem. That way the frontline bunchers are always new. We've been doing that for a few years now, and it has worked out very well."
An older Prentice 620 buncher is used as a filler as required, or for odd jobs on private land. All the logging gear runs on two shifts, but Vaughn says they have found that a slower pace serves the chippers best.
"We've tried all kinds of shifts, including 24 hours, seven days a week, but with the chippers we find that if you can get the loads you need running single shifts five days a week, it's best all around. The logging gear is run on doubles five days a week, because it's too expensive not to, and to tell the truth, we couldn't buy new chippers and afford to make the payments on single shift, at least not for the first five years."
The chipping crew targets 55 loads per week per chipper, and farms out all chip hauling except for one tractor and chip van. For logs, the weekly production target for veneer, pulp, sawlogs and stud sorts combined is 2 000 tonnes, which is hauled using the crew's seven self-loading log haulers. One float for the logging gear and two shunt tractors for the chippers keep gear moving between sites.
Lean but still mean?
With the addition of the new Levesque 240 processor, mounted on a Tigercat 860, the crew will now run three processors in the hopes of picking up extra volume.
"That's where that extra buncher comes in," Vaughn explains of the Prentice 620 FB. "Two bunchers followed by three processors will make a good match for us."
The Levesque processor is billed by Quadco as a robust 24-in processor with plenty of power for hardwoods and plenty of speed for softwoods. This is done with 1 600 cc Valmet motors that apply 9 750 lb of feed force and allow 15 ft/sec of feed speed. Designed by the same Levesque brothers who invented the Target, the 240 is aimed right at the mixed and big wood processing market already served by the Hornet (or older Target models).
This of course begs the question of why another head is needed at all. According to Vaughn, there are almost 2 000 reasons, as in the number of pounds that the mammoth Hornet outweighs the nimbler Levesque 240. While the Hornet tips the scales at over 8 725 lb, the Levesque weighs 6 800 lb. "The weight reduction was a big one for us," Vaughn notes. "There's a cost to swinging that extra weight around all day."
Vaughn expects the Levesque will be even better than his two Hornets for a number of reasons. "I like the fact that it doesn't have any sensors for the saw bar - just a simple trip switch instead. It also has big, heavy-duty Valmet motors, so the power we're used to with the Hornet is still there, and overall it is using the newest generation of components. And it's just as strong as it needs to be - I can't see where the lost weight is going to affect anything."
The lighter weight of the Levesque 240 will also allow some contractors to opt for smaller, more economical carriers. While not an issue for Hodgson's Chipping because of its carrier rotation strategy, lower capital and operating costs might attract other loggers to Tigercat 845 size models.
The new head had 300 hours on the dial when CFI spoke to Vaughn in early April, and so far has met his expectations. It has proven faster than the Hornet, he says, adding that the use of a photocell to find the butt on each new log has helped pick up extra production.
"When you pick the tree up, you don't have to make that first wasted cut to start the processing. You just push the button on your pre-set, and it finds the end of the log using the photocell. If you're in big diameter wood, making those cookies to start processing can take a lot of time."
Those first few hundred hours have also eased Vaughn's mind regarding length accuracy with the new head. He notes that 8-ft production was a no-brainer with the Hornet's mechanical plate system, while its measuring wheel did a good job on longer sawlog sorts.
"We do 8's and 10's, as well as sawlogs from 12 to 16 feet with diameter breaks that may change depending on what the different mills want. The Levesque head has a different measuring system (Allen Bradley length and diameter), so I was a little worried there. I did like the way the Levesque has a set of arms right where the measuring wheel is, so you never lose contact. It was one of the good ideas I saw in the head, and in the end I have been very happy with measuring accuracy."
The Levesque 240 is also available with an equalizing butt plate for multistemming, although this adds another 1 000 lb.
Future plans
Hodgson's Chipping continues to work at getting every last percentage point of efficiency out of its operation. As an example, the company is looking at adding MultiDAT recorders (black boxes) to its main logging gear to track downtime trends and causes. Vaughn expects to find some lost production there, and hopes to use the MultiDATs to create an operator incentive program to reward high uptime and machine cycles. Still, whether efforts like this will be enough to attract the next generation of loggers to the business is questionable, Vaughn admits.
"I have a son, and I can't see him going into this business the way it is going. I know a lot who feel the same. If someone has any brains and education today, why would you choose this lifestyle? There are just too many other options, and the rewards aren't there like they used to be to compensate for the long hours and work. We have a pretty good business, and we're in so far we have to keep going, but how you're going to convince young people to choose to get into this is beyond me."
Which in the end is too bad. Some 20 years from now, it's likely that Hodgson's Chipping will still have a couple of vintage bush chippers to pass on to the next generation.
"The weight reduction was a big one for us - There's a cost to swinging that extra weight around all day."