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Oregon State University: Open Minds, Open Doors.

About Oregon's Forest Products Industry

Contents




Introduction

“Where Timber is King!” and “Wood Basket to the U.S.” have been phrases often used to describe Oregon’s vast and valuable wood resource. Oregon has been the nation’s leader in lumber production for much of the past century. And, it’s the timber industry that has fueled the economic growth of the state for most of the past 150 years. A recognized leader in forest product manufacturing, Oregon is the source of many innovations found in today’s wood industry.

But times have changed. And, the timber industry has evolved, adapted, downsized, and consolidated as markets, technologies, raw material supplies and competition - both home and abroad - have changed.

Where sawmills were once relatively low-tech labor-intensive operations, they are now fewer in number but state-of-the-art, large-scale automated facilities.

While employment has declined in one sector of the industry (primarily lumber and plywood manufacturing), employment continues to increase in “value-added” manufacturing (for example, millwork, cabinets, and furniture).

And after all that change, Oregon still produces more lumber and panel products than any other state in the nation (WWPA Lumber Track, April, 2003). Oregon’s sawmills produce approximately 6 billion board feet of lumber each year – enough lumber to build about 400,000 3-bedroom homes.

The Industry’s Contribution to Oregon

Economists term the wood products industry a “basic industry.” In essence, this means the industry produces products sold outside the local area and as a result, brings new money into the area. Basic industries provide support for non-basic industries such as restaurants, groceries, and other service-sector businesses. These service-sector employers couldn’t exist, without the basic industry portion of an economy. Thus, the economic contribution of basic industries far exceeds their direct employment.

At one time, nearly ½ of Oregon’s manufacturing employees worked in the wood products industry. Total employment peaked at around 93,000 in 1978. Employment at the end of 2003 was approximately 46,000 with a total payroll of $1.7 billion. [Note: These figures do not include employment for forestry and logging.]

The primary factors accounting for declines in overall wood products industry employment are economic recessions (principally the recession of the early 1980’s), public timber supply constraints beginning in the early 1990’s, automation, and consolidation.

In the 1990’s, Oregon’s “high-technology” industries surpassed the wood products industry as the leading employer in the state. Such a fact, however, fails to recognize the regional importance of certain industry sectors. The majority of high-tech employment is concentrated around the Portland metro area. The wood products industry continues to be the dominant manufacturing sector in many counties in the state; wood products manufacturing comprises 50% or more of the manufacturing employment in 12 of Oregon’s 36 counties.

Oregon is the headquarters for a number of well-known forest products companies. Collins Products, Hampton Affiliates, and Roseburg Forest Products are examples of lumber and structural plywood producers. Columbia Forest Products, Timber Products, and States Industries make decorative hardwood plywood. Firms making moulding, doors, and windows include Contact Lumber, Bright Wood, and JELD-WEN – the State’s largest privately-held firm.

A Global Industry

The steadily increasing global demand for wood and paper products fuels demand for Oregon wood products. As an example, in the U.S., the average home size – a key driver in the consumption of wood products – has increased 48% since 1970 (while the average family size has decreased 16%). Thus, per capita consumption of wood continues to increase. And each American uses an average of about 750 lbs. of paper products each year.

Source:Western Wood Products Association

Wood products from Oregon are marketed throughout the U.S. and exported to every corner of the globe: Douglas-fir is still highly valued in Europe and Asia and pine moulding and millwork from southern and eastern Oregon mills provide a sizeable share of the raw material input for Midwestern door and window manufacturers – although the origins of this pine have changed.

At one time, the vast majority of the raw lumber for Oregon’s moulding and millwork producers originated from the ponderosa pine forests of Oregon’s high desert. Today, much of the material used by these mills comes from south of the Equator. For example, radiata pine (a tree native to the central California coast where it is known as Monterey pine) is produced in fast-growing, intensively managed plantations in several countries including New Zealand, Chile, Brazil and South Africa. New Zealand alone has approximately 4 million acres of radiata pine plantations.

Industry Detail – Definitions & Descriptions

There are many different ways to categorize the wood products industry, including:

  • wood species used (e.g. Douglas-fir or ponderosa pine);
  • location (e.g., Willamette Valley, southern, eastern, or coastal Oregon);
  • size of the mill (e.g., annual production or number of employees); and
  • type of product produced

A common set of categories based on product types produced is the following:

  • primary – sawmills and plywood mills
  • secondary – millwork, cabinet, and furniture producers
  • reconstituted products – particleboard or medium density fiberboard (MDF)
  • pulp & paper

"Road's Eye View #1"

Weyerhaeuser sawmill, Cottage Grove

As you travel down I-5, south of Cottage Grove, you will see the large sawmill and pile of logs on the west side of the Interstate. Have you wondered what they make here?

This is Weyerhaeuser’s Cottage Grove sawmill. The mill uses Douglas-fir logs to produce dimension lumber for construction. Much of the product of this mill ends up on the shelves of The Home Depot.

Many times, when people think of “the wood products industry”, they think only of sawmills or plywood mills. These “primary mills” begin with raw logs as inputs to their processes. As a result, these mills typically need quite a bit of land for storing logs and as a result are very visible in a community. Also, due to the economies of harvesting and hauling large items such as logs, such mills are typically located reasonably near the forest resource.

Secondary (a.k.a. “value-added”) mills, on the other hand, are often less conspicuous because they buy lumber and add value to it (hence, the term). Products produced by these mills vary from items like the trim around doors and windows, to the doors and windows themselves, cabinets, furniture, and hundreds of other items. The location for these mills is far less restrictive as they may buy lumber from all around the globe.

Reconstituted products include items like particleboard and medium-density fiberboard (MDF). These mills often use the waste products (e.g., sawdust, shavings, or chips) from primary mills or in recent years, recycled or reclaimed wood from pallets and crates and even demolished buildings. The essence of these products is that they reform waste or low-quality wood fiber into a useful product by applying adhesive and pressure. In recent years, some reconstituted product firms have faced challenges in finding raw materials. As the primary mills close, along with them go the waste products that these firms require.

Also, there are a number of pulp & paper mills in Oregon. The vast majority of the raw material for making paper is the residue from other mills – primarily chips from sawmills. While there are only a half-dozen or so pulp mills in the state (firms that dissolve or grind wood chips into pulp), there are nearly 60 firms producing paper and paper products such as linerboard (the outer surface of cardboard boxes), newsprint, and writing papers.

Wood Species and Their Uses

The primary commercial species in Oregon are the softwoods, a.k.a. conifers or evergreens. And king among the softwoods is Oregon’s state tree, the Douglas-fir. Wood from this tree species is used all around the globe as construction lumber, plywood sheathing, interior trim, and for paper. Douglas-fir is especially known for its strength and stability. In fact, compared to other North American woods, Douglas-fir has among the highest strength to weight ratios.

Western larch, also known locally as tamarack, is used for many of the same purposes as Douglas-fir and is often sold in combination with this species.

Western hemlock and the true firs (for example, grand fir, white fir, Pacific silver fir, noble fir, and California red fir) are used for construction lumber, moulding & millwork, and paper. These species are often sold combined as “Hem-fir.”

Ponderosa pine is a prized species for moulding & millwork (for example, interior trim, doors, and windows), shelving and paneling. The majority of ponderosa pine in Oregon grows in the central and eastern parts of the state, but a genetic race of this species adapted to grow in wetter western Oregon - the Willamette Valley strain - is being planted and may be the beginnings for a new wood products supply in future years.

Oregon is also home to a number of hardwood or broadleaf trees (e.g., red alder, bigleaf maple, Pacific madrone, poplar or cottonwood, and Oregon white oak), however these species, with the exception of alder, have received far less commercial use than the softwoods or conifers. Alder is used for furniture, cabinets, veneer for plywood, and paper. Other species like madrone, maple, and white oak are used for flooring and cabinetry.

Some “up and coming” species for commercial use include western juniper and hybrid poplar. Juniper, an aromatic species related to eastern (a.k.a. Tennessee or aromatic) redcedar is being used for furniture, flooring, paneling, animal bedding, and to build log homes.

Hybrid poplars are grown like agricultural crops. Large pulp & paper firms established these plantations as a source of raw material. Other higher value uses for poplar such as moulding, millwork and upholstered furniture frames are now being explored.

"Road's Eye View #2"

Weyerhaeuser paper mill, Albany

As you drive along I-5 on the north end of Albany (near exit 238) you’ve undoubtedly seen one of Oregon’s pulp & paper mills. Have you wondered what they make here, why they need such a mountain of wood chips, and perhaps… what is that smell?

This mill is Weyerhaeuser’s Albany Paper Mill. The mill uses Douglas-fir chips to produce about 1600 tons per day of kraft paper used for linerboard – the outer surfaces of corrugated containers (a.k.a. cardboard boxes) and paper for grocery bags.

The mill also recycles old corrugated containers (over 10,000 truckloads each year!). About 50% of the pulp they use comes from recycled materials.

What about the smell? Kraft paper mills use sulfur-based chemicals to “dissolve” wood chips into fibers for papermaking. Hydrogen sulfide and methyl mercaptan (the compound that gives natural gas its smell) are given off as byproducts. The human nose is particularly sensitive to these compounds – we can detect the smell when concentrations are as low as one part of sulfur compound per billion parts of air.

Location – what gets made where

Regardless of product produced, the Willamette Valley is home to a sizable portion of Oregon’s wood products firms. About ½ of the state’s sawmills are in the Willamette Valley. Veneer (thin sheets of wood used to produce plywood and other products) production is concentrated in the Willamette and Rogue Valleys. Although the majority of the state’s larger moulding & millwork plants are in eastern Oregon, about 2/3 of the total moulding & millwork firms are in the Willamette Valley. About 2/3 of the kitchen cabinet production is in the Willamette Valley as well. Furniture manufacturing is even more concentrated – about ½ the furniture makers are in the metropolitan area of Portland.

Industry Changes – Adaptation and Innovation

Source: Oregon Employment Department

Although the number of sawmills in Oregon has declined significantly, the production per sawmill has increased substantially due to the use of state-of-the-art processing technology. Further, many firms have adapted to changes in raw materials and markets via product innovations.

Many product innovations are composite products - combinations of solid wood or wood fiber. For example, plywood is made from gluing together layers of wood veneer. Laminated veneer lumber (LVL) is similar to plywood, however the product is typically used in applications where lumber has traditionally been used. LVL, an engineered wood product (EWP), is commonly used in wood I-beams used for joists in homes, and large pieces are used as beams or headers for large windows or doors.

Composite products also include combinations of wood and other materials such as plastic.

Profile wrapping is another example of a product innovation that involves literally wrapping lower-valued substrates (e.g., finger-jointed wood pieces or MDF) with a thin layer of wood veneer such that the end product looks like a solid wood piece.

Many processing innovations have been driven by the need to efficiently process smaller diameter logs. The shift from public to private timber sources (both industrial and smaller family-ownerships) beginning about 1990, resulted in the utilization of smaller diameter and younger trees than had been the case in past years. In fact, by year 2000 it had become much more difficult to find markets for logs greater than 30 inches diameter since so many of the mills had already converted to smaller log processing.

Sawmills have invested a huge amount of capital in sawing and material handling technology to enable them to process the smaller logs rapidly and efficiently. For example, many mills use lasers and video cameras to provide a digital image of a log’s shape. Before saws ever touch the log in the mill, computer systems simulate all the possible ways the log could be cut into lumber. The log is then sawn following the optimal solution.

Scanning to determine log shape

Selection of high strength veneer for laminated veneer lumber (LVL) is another example of the use of technology in Oregon mills. Ultrasonic sound waves are sent through sheets of veneer to identify denser, more desirable pieces.

Secondary/ value-added wood products firms also use machine vision technology to scan boards for knots and other visual defects and then determine the optimal way to cut the boards to produce the desired end products (e.g., parts for doors or windows).

Sustainability and Oregon’s Forest Products Industry

Oregon has stringent forest practices laws that are unmatched in many states and most countries around the world. In a global economy, this high environmental performance can be a competitive disadvantage since it generally comes at a higher cost. The state of Oregon is seeking to turn this potential disadvantage in the marketplace into an advantage by targeting markets that value products grown in environmentally well-managed forests. Long known as a state that is “green and clean”, this reputation could help future wood product marketing endeavors.

Forest Certification

Forest certification, or green certification as it is sometimes called, is an attempt to identify forestland that is well managed. The main issue behind forest certification is a need to provide objective evidence that forest products are being produced without harm to forests or to the natural and human systems that they support. The evidence of this is often documented in an on-product label, or ecolabel. Forest certification and a supporting ecolabel allow forest industry companies to use marketing as a mechanism for supporting sustainable development in society.

Marketing activities build a bridge between the company and its many stakeholders, especially its customers. The function of marketing is to analyze customer needs and transform them into business opportunities. If customers are environmentally conscious and want to make choices supporting sustainable development, a company can transform these environmental requirements into business opportunities. The State of Oregon and various members of the forest industry are exploring the potential to use certification and/or the Oregon Forest Practices Act as a mechanism for recognition in the marketplace via “Brand Oregon”.

For More Information:

"Road's Eye View #3"

Potlatch Hybrid Poplar Plantation, Boardman

As you drive along I-84 near Boardman, you will see a forest that seems a bit out of place – right in the middle of the high desert. You’ll probably also notice that the trees are all about the same size and are in nice evenly-spaced rows.

This “forest” is actually Potlatch Corporation’s 17,000-acre hybrid poplar farm. The trees were originally intended to provide wood chips for the company’s paper mills. However, as prices for wood chip dropped, the company began to explore other products and markets for the wood.

The trees are irrigated via a complex system involving 18,000 miles of drip line tubing and 24 million drip emitters. The adjacent Columbia River provides the irrigation water.

And these trees grow fast - about 10-12 feet in height each year. They will reach harvestable size in about 10 years.