Author: saalasti

Are you looking to optimize your biomass pelleting process and improve its efficiency? Focusing on the mechanical dewatering phase of pellet production is crucial when aiming to enhance biomass capacity and quality. 

The secret to enhanced productivity isn’t about intensifying the drying process but working smarter. The answer lies in heavy-duty high-pressure press technology, which enables you to increase capacity while operating more energy-efficiently. 

Still wasting energy on traditional drying? 

Traditional biomass pelleting processes rely heavily on thermal drying. However, this approach has significant drawbacks: it consumes vast amounts of energy and leaves much to be desired regarding production efficiency and material quality. 

What if you could skip most of that energy-intensive process? What if you could utilize mechanical pressing to enhance the entire thermal drying process while optimizing your production flow? 

Modern mechanical dewatering technology offers an efficient alternative by removing water before thermal drying, significantly reducing energy requirements. When mechanical dewatering minimizes the load on your thermal dryer, the freed-up drying capacity becomes available for processing additional biomass. This translates into a significant production increase using your existing equipment. 

For biomass processors and pellet manufacturers, the benefits are clear and measurable: 

• Increased production capacity without investing in a new dryer. 
• Higher pellet sales volume and market reach. 
• Improved cash flow from additional production. 
• Lower investment compared to a new thermal dryer. 

The mechanical press offers a cost-effective alternative to investing in additional thermal drying capacity, making it an attractive solution for businesses looking to expand their production. 

Our biomass pelleting optimization delivers proven results: 

• Up to 50% reduction in energy consumption 
• Significant increase in production capacity using existing equipment 
• Enhanced product quality through improved process control 
• Year-round stable production, regardless of seasonal variations 

These benefits can be realized without replacing your existing production lines. The addition of mechanical dewatering technology enhances the efficiency of your current thermal dryers by reducing their workload.

See also: Dewatering press: What are the benefits of mechanical drying?

New generation solution for biomass pelletizing: Hippo Press 

The Saalasti High-Pressure Press revolutionizes biomass pelleting by efficiently reducing moisture content in biomass materials such as wood chips and sawdust. 

For pellet manufacturers, the benefits reach far beyond simple dewatering. The press’s mechanical action partially crushes the wood chips, increasing the surface area for more efficient thermal drying. This creates consistently higher-quality input material for your pelletizing process. 

What matters most for your production is reliability and consistency. The press delivers stable moisture content regardless of seasonal variations in raw material, ensuring your downstream process runs smoothly with minimal interruptions. The pre-crushed material reduces wear on your hammer mills and pellet presses, leading to lower maintenance costs and extended equipment life. 

The technology particularly shines in demanding production environments. Its robust design effectively handles feedstock impurities while delivering homogeneous output that optimizes the entire pelleting process. The result is more consistent production rates and higher-quality pellets. 

Read more about Hippo.

Hippo enables your plant to process more material through your current dryer system, increasing throughput and producing more pellets per time unit.

Biomass pelletizing success story: boosting production without the need to add heat 

Van Roje, a German softwood sawmill and pellet manufacturer, needed to double its pellet production from 40,000 to 80-90,000 tonnes annually. However, its existing belt dryer and heating plant faced capacity limitations. 

The company implemented Saalasti High-Pressure Dewatering Press 1803 “Hippo” as a solution, removing approximately half of the water from wood chips and sawdust before thermal drying. 

With the Hippo press, Van Roje increased their production from 60 to 90 tonnes using the same amount of heat without requiring additional combustion systems or dryer investments. 

The solution enabled year-round steady operation, eliminating previous seasonal capacity fluctuations that had reduced winter production by up to 50%. 

Read the whole story! 

Calculate your potential? 

Our optimization service helps you understand the full potential of your current drying process. We’ll analyze your monthly energy costs and calculate how much mechanical dewatering technology could increase your production capacity. 

Our team of experts is ready to analyze your current biomass pelleting process and show you exactly how much you could: 

• Increase your production capacity. 
• Reduce your energy consumption. 
• Improve your bottom line. 

Don’t let your competitors get ahead. Contact our biomass pelleting experts today and discover your potential!

Is your company seeking new ways to process textile waste and improve your textile shredding process? A new era of textile waste processing is beginning, especially in Europe, where the aim is to reduce textile waste through a circular economy. Textiles should not be seen as disposable waste but as valuable raw materials that can be reused in various applications. 

Textile recycling creates new opportunities for businesses. Recycling requirements often encourage companies to develop innovative ways to utilize textile fibers. Is your company participating in this?

Learn why textile recycling is a growing circular economy business opportunity and how a high-performance textile shredding machine can help you launch a new business efficiently. 

At Saalasti, we support new ways to utilize textile fibers. The key is technology and machines that enable industrial-scale textile processing to be scaled flexibly and cost-effectively. Our high-performance shredding machines can significantly improve your textile recycling process. These machines are designed to meet the emerging industrial need for efficient and cost-effective textile processing. 

EU regulations driving the change in textile fiber recycling 

The amount of textile waste is a global problem, and the EU has taken decisive action to prevent waste mountains. The figures show that now is indeed the right time. 

The European textile industry generates over 16 million tons of textile waste annually, with only about 25% recycled. According to EU statistics, approximately 5 million tonnes of clothing are discarded each year in the EU—around 12kg per person—with only 1% of material in clothing being recycled into new clothing. 

To address this growing challenge, the EU has implemented the Strategy for Sustainable and Circular Textiles as part of the European Green Deal and Circular Economy Action Plan. 

Key regulatory developments include: 

• Separate collection of textile waste will be mandatory across all EU member states.
• Textile waste should be processed within Europe rather than exported to other regions.
• By 2030, all textile products placed on the EU market must be durable, repairable, and recyclable.
• Products will need to include significant recycled fiber content.
• New products must be free of hazardous substances and produced respecting social rights and the environment.

These regulations represent both a challenge and an opportunity. 

Textile recycling has a lot of industrial opportunities 

With new EU regulations demanding local processing of textile waste and only 1% of clothing currently recycled into new garments, textile shredding represents a crucial opportunity for forward-thinking businesses. 

Companies must adapt their waste management processes. However, they can also explore new revenue streams through new opportunities, with EU data suggesting that 20 to 35 jobs can be created for each 1000 tonnes of textiles collected for reuse. 

What to do with shredded textile fiber? 

Textile waste can be processed for a variety of applications. Modern textile shredding machines can handle different materials, including various fibrous substances and textiles such as cotton and blended fabrics. 

When processed with a textile shredder, waste textiles become valuable resources. The separated fibers can be repurposed for numerous applications, including: 

• Raw material for new textile production 
• Building insulation 
• Automotive components 
• Furniture padding 
• Composite materials 

Where could your company further refine textile fiber? We’re happy to participate in the planning process that considers the desired properties of the textile fiber.

Advanced textile shredding machine solutions 

Investing in large-scale production requires efficient machines for a new textile recycling business. This is where Saalasti’s expertise becomes essential. 

Saalasti Cutter V, initially designed for demanding biomass applications, has proven remarkably effective as a textile shredding machine. 

This versatile equipment features our innovative Multitool rotor system that allows for easy adaptation to different materials—including various types of textiles: 

• Cotton fabrics 
• Synthetic fibers 
• Blended textiles 
• Production scraps 
• Post-consumer clothing 

Key advantages of using Saalasti Cutter V for shredding textiles include: 

• Adaptability: The Multitool rotor system can be configured for various textile fiber types.

• High-capacity processing: Handles industrial volumes efficiently (capacity 30–450 loose m3 per hour as needed). 

• Energy efficiency: Electric motor design can help save energy and fossil fuels.

• Robust construction: Built for continuous industrial operation with minimal downtime.

• EasyRelease technology ensures that even materials that are difficult to process are cut properly.

Shredded textiles before and after:

Saalasti machines are built to last and evolve with changes if the need to process new fibrous materials arises. 

The Saalasti textile shredder machine efficiently converts textiles into fibers suitable for new production processes. Our machines can handle materials ranging from clean textile scraps to post-consumer clothing, producing consistent, high-quality fiber output. 

Learn more about the machine: Industrial Wood Cutter 

Read also how our subsidiary’s automatic baling, dewiring and bale opener solutions can boost the processing of textile fiber: Cross Wrap & textile recycling. 

Validate your materials with textile fiber testing 

Can the textile shredder machine handle your material effectively? Let’s test it! We can test the suitability of almost any fibrous biomass for our machine before purchase so you can be sure the solution works for you. 

Read more about our testing laboratory here. 

By incorporating a textile fiber shredding machine into your operations, you not only comply with upcoming sustainability regulations but also create new value streams and contribute to the circular economy.

Ready to explore new textile fiber business opportunities? 

Would your company like to learn more about the benefits of textile shredding for your operations? Are you seeking partners to enhance your new business? 

Contact our team to discuss your needs and discover how our textile shredding machines can help transform textile waste into valuable resources. 

Contact us here!

Are you curious about the potential of your fiber-rich biomass material? Do you want to enhance your industrial biomass processing capabilities? 

The biomass test laboratory provides validated results before you invest. Discover how our testing facility helps you develop processes and reveal the hidden potential in new materials. 

Our biomass testing facility is globally unique. We can test countless types of fibrous biomasses and discover new market potential.

Why test your biomass in a laboratory? 

When processing large volumes of biomass, ensuring your process works before investing in a processing solution is crucial. 

Will your material achieve the desired dryness? Can your agricultural residues be efficiently compressed? Can a new innovative material be processed into valuable output? The answers can be found through testing. 

Our unique biomass test laboratory houses prototype-scale equipment that mirrors our industrial-scale machines. This allows you to test different materials and processes on a smaller scale before implementing them in full-size operations. 

The advantages of biomass testing: 

• You can verify the feasibility of your process with minimal risk. 

• We can optimize the parameters specifically for your material. 

• You receive documented performance data to support your investment decision. 

This scientific approach to process validation has helped numerous industrial operations worldwide transform their biomass handling concepts into successful full-scale implementations.

Even seemingly similar materials, like pine from different geographical regions, can behave differently in processing. Pine from Nordic forests has distinctly different properties than North American pine, which affects its performance in industrial processes.

Testing your specific material under controlled conditions is crucial for your project’s success.

Through laboratory testing, you gain verified confirmation that your target performance values can be achieved. As a result, you can: 

1) Validate materials and processes at prototype scale. 

2) Minimize investment risks. 

3) Optimize process parameters before full-scale implementation. 

The test results establish guaranteed performance values that become part of your contract. 

With decades of expertise in biomass, we demonstrate process performance at a prototype scale. Our biomass test laboratory shows precisely how your material will perform before you commit to full-scale equipment.

From wood bark to innovative materials, we can test it! 

We can process practically any fiber-rich biomass in our test laboratory, which is one of its kind worldwide.

The most common materials we test are plant-based fiber materials: 

• Traditional wood-based materials (bark, chips, sawdust) 

• Agricultural residues and straw 

• Sugar cane 

• Various types of organic waste 

Additionally, we openly test other innovative materials, such as: 

• Emerging fiber-rich materials, like textiles. 

• Industrial by-products like brewery spent grain. 

• Specialized plant materials, such as tomato stems. 

If your material is not on the list, don’t worry, we can still figure out if it suits the process.

Turn your biomass concept into guaranteed performance 

Our biomass test laboratory offers valuable data and insights for confident decision-making, whether you are developing new processes or optimizing existing ones. 

We guide you from initial material assessment to detailed process validation, helping you understand the full potential of your biomass processing concept. 

In our biomass test laboratory, we follow a proven methodology:

• Material characterization and analysis.
• Process testing at prototype scale.
• Performance optimization.
• Scale-up parameter definition.
• Guarantee value determination.

Each step in our laboratory testing process builds confidence in your investment decision while minimizing risks!

The process of testing your material in our biomass test laboratory follows clear steps:

• Send us a representative sample of your biomass material. Our experts will advise you on the required sample size and shipping instructions.
• Material handling. We follow necessary biosecurity protocols. This ensures we meet the requested safety standards while maintaining your material’s testing properties.
• Testing. We conduct comprehensive tests using our prototype-scale equipment, following the testing protocol for your specific needs. Our experts monitor and document every aspect of the process.
• Analysis and Results. You receive a detailed analysis of your material’s performance, including
  performance data
  process parameters
  scale-up recommendations
  documented test results that define guaranteed values for your contract.

Not to forget development opportunities! During testing, we may identify new potential applications for your material. In such cases, we can initiate a structured product development project together, following our Lean Service Creation methodology:  

• IDEA – Exploring new possibilities 
• VALIDATION – Confirming market potential 
• PILOTING – Testing in real conditions
• GROWTH – Scaling successful solutions 

This comprehensive approach ensures you not only validate your current process but also discover new business opportunities. Our laboratory specialists actively test different types of biomass worldwide, helping us develop sustainable solutions for various industrial needs. 

Laboratory test results define guaranteed values for your contract.

Let’s test it! 

Do you want to know how your biomass can perform to its full potential?  It is possible in our unique laboratory!

Contact our biomass test laboratory team to discuss your specific material and requirements. 

Contact us here! 

>> Get to know a new-generation High-Pressure Press Hippo 

If you work at a thermal or condensing power plant, you’re likely seeking solutions to enhance the overall efficiency of your facility and make better use of biomass energy. One effective way is optimizing the moisture content of biomass. 

However, if you are unfamiliar with the innovative solutions the market offers, there is a risk of missing out on energy savings in your biomass operations without even realizing it.

In this article, we focus on the advantages of biomass energy and explain how thermal power and condensing power plants can enhance their bioenergy utilization by optimizing the dry matter content of biomass. 

Plants in Central Europe can significantly boost their operational efficiency by focusing on moisture reduction within the biomass drying process, maximizing the advantages of biomass energy as a renewable resource.

Boosting the advantages of biomass energy in central European countries – find the solution in mechanical drying

In the Nordic countries, using district heating networks for heat recovery and recycling is common. However, in many Central European countries, this infrastructure does not exist. Thermal and condensing power plants in these regions must look for other methods to improve energy production efficiency, such as considering the advantages of biomass energy.

Using biomass as an energy source reduces CO2 emissions and fuel costs due to decreased reliance on fossil fuels. The moisture content of biomass affects its utilization in energy production, so power plants that use biomass as biofuel benefit from drier material.

Drier biomass leads to more efficient energy production, as less energy is required to evaporate water, allowing more energy to be utilized for actual heat generation. 

For example, when biomass contains 50% water, a significant portion of the dry matter’s calorific value is wasted on evaporating water, leaving less energy for heat production. Mechanical drying helps overcome this issue by reducing the amount of water that needs to be evaporated. When the biomass is dried before being used as a fuel, less energy is required for water evaporation, leading to a more efficient combustion process.

Energy losses in biomass evaporation can be as high as 40–60%, depending on the dry matter content. By improving the drying process, biomass becomes more energy-efficient, cutting biomass consumption by up to 10–15% while maintaining the same energy production.

Saalasti’s machines are specifically designed to improve the dry matter content of biomass, making them a valuable long-term investment for thermal and condensing power plants seeking to utilize the advantages of biomass energy.

By crushing and chipping biomass, our robust machines increase the surface area for drying, accelerating moisture removal. Additionally, our powerful pressing technology enables mechanical water removal without heat, further reducing energy consumption and improving overall process efficiency.

Thermal vs mechanical drying – basic facts:

• Thermal drying uses heat to remove moisture from biomass, typically consuming more energy. 
• Mechanical drying involves pressing or squeezing water out of biomass without heat, conserving energy and making it ideal, for example, in pre-processing stages. 
• When biomass is processed before combustion, mechanical drying can increase process capacity without increasing energy consumption. 
• Learn more about the benefits of mechanical drying here.

Saalasti’s machines are ideal for various applications, including pellet production, biochar production, and energy production, as well as utilizing press water for purposes like fertilizer and feed production.

Read more about our customer stories: How to turn biomass into value? 

Tackling the typical biomass moisture challenges: how Saalasti machines maximize biomass energy advantages? 

If your plant uses thermal drying for biomass, you might wonder why you should invest in new equipment. However, thermal drying is often a bottleneck for energy efficiency due to its high energy consumption. 

A mechanical press can significantly increase drying capacity while enhancing overall energy efficiency. Our presses also ease hammer mills’ workload by reducing the biomass’s moisture content beforehand, improving their operational efficiency and longevity.

When optimizing the advantages of biomass, one common challenge is managing the residual water, or press water, from the drying process. This water must be treated properly before it can be discharged into water systems. At Saalasti, we help our customers find tailored water treatment solutions that vary in scale and cost, ensuring environmental compliance while maintaining operational efficiency.

Saalasti’s solutions for utilizing biomass energy advantages are scalable to fit different plant sizes and biofuels. Our equipment can also be modularly integrated into existing processes to increase capacity without significant downtime.

 Contact our sales team for more details.

Saalasti Hippo 1803 – a new-generation high-pressure press offers huge energy-saving potential 

Compared to thermal drying, Saalasti’s solutions offer significantly lower energy consumption and achieve much better dry matter results than other mechanical presses. Additionally, Saalasti machines are easy to install due to their compact footprint, considerably smaller than thermal systems. 

For example, our latest innovation, High-Pressure Press 1803, Hippo, dramatically reduces the moisture content of organic fibre-based biomasses such as wood chips and sawdust. The press suits many industries where fiber-based biomass requires an energy-efficient drying method. 

Read more about Hippo.

How to measure and monitor biomass dry matter content

You can evaluate the moisture content of biomass using different methods to identify opportunities to utilize biomass energy advantages better.

• Regular laboratory measurements: Gather accurate and reliable data on the biomass dry matter content with frequent laboratory tests. 
• Process performance: Monitor the energy consumption of thermal drying processes. Higher energy consumption may indicate that the biomass contains more moisture than expected.
• End-product quality: Evaluate the quality of the final product, such as pellets. It often indicates how effectively moisture has been removed from the biomass.

More than just saving energy: the additional advantages of biomass drying

In addition to energy production, drying biomass offers several other benefits.

One of the key advantages is that log piles and forest residues can be transported to the facility fresh, without the need for prolonged drying along the roadside. 

This practice helps reduce material losses due to natural decomposition and minimizes the breeding of harmful organisms, such as fungi and insects, that thrive in moist conditions. By avoiding unnecessary exposure to environmental conditions, the quality and quantity of various biomass materials are better preserved, resulting in more efficient use of resources.

From a processing standpoint, the mechanical properties of processed biomass are also significantly improved when biomass is dried efficiently. Drying enhances both biomass’s chemical and mechanical handling characteristics, making subsequent processing – such as grinding, chemical treatment, or pelletizing – much easier and more efficient.

Improved mechanical strength and uniformity of the material can reduce wear and tear on equipment, lower operational costs, and increase throughput efficiency.

Drying biomass before further processing saves energy and enhances the entire production chain, improving performance and sustainability.

Biomass energy advantages in action: Case Van Roje 

In wood pellet production, the German company Van Roje raised the production capacity from 60 to 90 tonnes with the same volume of heat and without additional combustion systems. This was possible with Saalasti High-Pressure Dewatering Press 1803 “Hippo”, which removes approximately half of the water content of the wood. 

The Van Roje case highlights the practical advantages of biomass energy. Investing in Saalasti technology has allowed Van Roje to improve energy efficiency and achieve higher capacity with stable, reliable, and sustainable processes. 

Read the customer success story.

Interested in learning more about biomass energy advantages?

Contact our sales team to learn how we can enhance biomass energy efficiency in your processes. Our innovative solutions help optimize drying and reduce energy costs, driving sustainability and performance improvements.

Get to know Saalasti products.

See our customer stories here!

When it comes to industrial maintenance, not all services are created equal. If you want to ensure that your biomass processing equipment operates with consistent, high-level performance not just for a couple of years but for decades, predictive OEM maintenance is the best investment you can make for your machinery.

Even the most advanced biomass equipment doesn’t operate on a simple “plug and play” basis for years. The well-known secret to its sustained performance is professional maintenance.

Read on to discover how quality maintenance isn’t just about reacting to problems but primarily about anticipation and cost-efficiency considerations.

At Saalasti, we offer cutting-edge maintenance services for our biomass crushers, cutters, and other industrial equipment. Our primary goal is to keep your operations running smoothly.

It’s crucial for us to provide local maintenance services in local languages. That’s why we have operations in the Nordic countries, Spain, Chile, and North America.

Predictive maintenance: not only fixing problems but ensuring the best performance

In the biomass industry, one thing is sure: equipment reliability is the key to success. The best performance cannot be achieved by merely reacting to issues, as if, for example, the wear of a critical spare part has not been predicted; in the worst case, one may have to wait weeks or months for it.

There are several compelling reasons why we advocate for predictive maintenance.

First and foremost, it minimizes unexpected breakdowns by catching issues early, drastically reducing the chance of sudden failures. This approach also optimizes equipment lifespan, as regular, targeted maintenance keeps your machinery running at peak performance for extended periods.

Additionally, predictive maintenance leads to reduced overall costs. Predictive maintenance allows you to budget maintenance needs more accurately and avoid significant surprises. We help you save on repair and operational expenses by preventing major breakdowns and optimizing maintenance schedules.

Finally, this strategy significantly improves production efficiency. You gain more production time with less downtime, ultimately boosting your bottom line.

Thus, predictive maintenance isn’t just about fixing problems—it’s about enhancing the performance and profitability of your entire operation. 

Maintenance contracts are predictive maintenance at its best

Maintenance contracts mean one less thing to worry about in your day-to-day operations. We take on increased responsibility, proactively managing your equipment’s maintenance throughout its entire lifecycle. You no longer need to stress about when the next service is due or what maintenance your equipment might need. 

Here’s why a maintenance contract can be a game-changer for your operations:

Proactive care: With a maintenance contract, we take proactive responsibility for your equipment’s lifecycle maintenance. You no longer need to worry about when the next service is due—we’ve got it covered.

Regular health checks: Most often, we perform semi-annual and annual inspections, during which you receive reports and essential calculations about the condition of your machine. This allows you to anticipate maintenance and spare part needs far into the future.

Long-term planning: We help you plan for major overhauls and upgrades years in advance, making it easier to manage your capital expenditure.

Predictable costs: No more surprise expenses for unexpected breakdowns, as due to anticipation, you’ll know, for example, when it’s the right time for parts replacement.

Priority service: We agree on precise response times that meet your needs to minimize production line downtime.

Customized solutions: Whether you have a single machine or multiple facilities, we can create a contract that perfectly fits your needs. We’ve got you covered, from essential preventive maintenance to comprehensive predictive care.

Continuous improvement: We always seek ways to improve our services, technology, and processes in cooperation with our customers.

Read also: How to maintain the maximal performance of Saalasti machine? Maintenance and lifecycle services at your service

Why choose international maintenance services straight from the manufacturer?

As an Original Equipment Manufacturer (OEM), we bring decades of solid expertise to the field.

Here’s why OEM services stand out.

Deep equipment knowledge: Our technicians know your machines inside and out because, as machine builders, our company has the most significant expertise in our machines. This knowledge allows for more accurate diagnostics and efficient repairs.

Access to original spare parts: We maintain a vast inventory of spare parts in our warehouses, ensuring quick replacements and minimizing downtime. This allows us to significantly reduce delivery times for our clients. While it’s not feasible to stock every possible component, we strategically store a wide range of items, with specific critical components always available. 

Specialized tools and techniques: Our maintenance procedures are designed for our equipment and perfected during decades of customer service, guaranteeing cost-efficient and safe maintenance services.

Long-term cost-effectiveness: OEM services prove more economical over time by preventing major breakdowns and extending equipment lifespan.

Read more about our services.

Why choose Saalasti’s industrial maintenance services?

Our global presence allows us to offer versatile services:

Worldwide reach local expertise: With locations around the globe, we provide quick service in your local language. Our locations are Finland, Sweden, Spain, Chile, and Canada (North America). 

Customized maintenance contracts: We tailor our services to your specific needs, whether you have a single machine or multiple facilities.

Proactive spare parts management: Our extensive inventory and global network ensure quick part replacements when needed.

Rapid response and support: We pride ourselves on reacting to issues within 24 hours, minimizing your downtime.

Flexible options: While we recommend maintenance contracts for optimal care, we also offer on-demand services for those not yet ready for a long-term commitment.

Partner with us for optimal machine performance

Our predictive maintenance services offer more than repairs; they provide peace of mind. You can focus on what you do best—running your business—while we ensure your equipment is always operating at peak performance.

Ready to improve your industrial maintenance? Contact us today for a personalized maintenance assessment. Let’s collaborate to keep your operations running smoothly, efficiently, and profitably.

See our customer stories here. 

A high-performance, heavy-duty chipper can be a game-changer for large-scale operations, such as pulp, paper and pellet facilities. A properly maintained machine can last for decades, ensuring you can process even the most challenging types of wood into the right chip size.

But what sets a high-capacity vertical chipper apart, making it a game-changing factor for large-scale operations? Let’s dive in.

What makes the difference when choosing a heavy-duty chipper? 

It’s essential to consider the investment decision for a wood chipper carefully. You want a choice that meets your current and future needs while enabling competitive production. 

When making your selection, look for these features in wood chippers

Capacity. One crucial aspect is ensuring the machine can handle various materials, withstand high demand spikes, and stay active when scaling up your production. A high-capacity, heavy-duty chipper is also more cost-effective in the long term, streamlining production processes and reducing operational costs per unit.

Saalasti chippers offer remarkable capacity and incorporate robust overload protection. If substantial metal objects enter, specialized shear pins break, releasing the anvil and grate. This action triggers limit switches connected to these components, promptly shutting down the electric motor to prevent damage.

Robust design. Because you don’t want unexpected production interruptions, frequent repairs, or premature equipment replacement in your operations! A robust, heavy-duty wood chipper ensures long-term reliability, high performance with tough materials, and an extended operational lifespan.

Saalasti vertical crusher-chipper is the most robust crusher of its size. Its simple design features only one moving part: a rotor machined from solid steel.

High performance throughout the seasons. High availability maximizes productivity and returns on investment. This reliability is especially vital in industries where the chipper is integral to a more extensive production process, such as pulp and paper mills.

Saalasti chippers stand out from other machines by using a solid steel rotor with high inertia instead of a drum rotor. This design enables the machine to handle variations and surges in material feed by evening out the load.

Suppose there’s an excess in the feed. In that case, the rotor’s inertia processes the material spikes without significantly impacting the power supply, preventing the machine from stalling. 

Easy-to-use. User-friendly features minimize the learning curve and the risk of errors, ensuring that a wide range of personnel can operate the equipment safely and effectively. 

Operating Saalasti machines requires minimal operator supervision. The considerate design helps maintain a tidy work environment and simplifies upkeep, improving overall safety. Fewer operator interventions reduce the risk of accidents and errors, leading to a safer workplace. 

Saalasti machines also have safety mechanisms to reduce damage if large metal or rock pieces are accidentally fed. Given their high hourly tonnage, the safety features are designed for quick resettings.

Maintenance service and spare parts. A machine is often said to be only as good as its maintenance services. Professional maintenance ensures your machine operates reliably for decades, even if your production conditions change.

The worn parts of the Saalasti chipper can be changed and, in many cases, rebuilt and reused. Though the spare part requirement is low, the chipper is so robust and heavy-duty that most parts can not be broken.

We offer blade replacements, maintenance inspections, servicing, and OEM spare parts, which are the best choices for your machine. Discover our maintenance services.

Versatility. What do you do if you want to change the material, particle size, or capacity? You don’t replace the entire machine; it adapts to your needs. The Saalasti chipper’s adaptability ensures you can easily handle any changes in your production needs. 

By changing the blade, the machine reveals entirely new capabilities.

Thanks to the Multitool Rotor, the Saalasti V Crusher is also an adaptable chipper: by changing knives, the machine operates as a chipper or a crusher. This unique feature allows for different blades or cutter bars without changing the rotor, guaranteeing the correct particle size and capacity, no matter the material. 

Hard-working with different materials. Do you operate with challenging materials like sticky or wet substances or eucalyptus? These can lead to blockages, especially when dealing with materials whose fibres can clog the machine. To make sure, choose a machine that can be configured and is adaptable to different materials. Also, it is essential to note that the blockage is only sometimes in the chipper but elsewhere in the production line – we can help you find it.

The solution is to choose a machine that can process various materials. Saalasti machines are suitable for different wood species and other fibrous agricultural products.

Saalasti chipper can be configured to process complex, sticky materials quickly. We have the expertise to handle this, allowing for the processing of often wet materials without causing blockages.

Energy efficiency. Efficient energy use reduces electricity or fuel expenses and contributes to sustainable practices. Energy efficiency can be improved by selecting chippers with advanced electric motors, maintaining sharp blades, and regularly servicing the equipment to ensure optimal performance.

Our machines use a cutting action instead of the energy-intensive crushing mechanism of traditional hammer mills, significantly reducing energy consumption. This results in lower operational costs and enhanced sustainability. Also, stationary machines are substantially more energy-efficient because they operate on electricity instead of fossil fuels.

Read also: Mobile crusher or stationary crusher? 

The muscle behind the chipping process: Saalasti heavy-duty chippers

Even if we say so ourselves, the Saalasti V Crusher-Chipper meets all the features above, and there are many reasons why it has become the market leader.

• Long history and reliability. The machine has become an industry standard in many countries. Our oldest machines have been in use since the 1990s.
• It processes various materials, such as bark and wood by-products from debarking plants, screening rejects, trees and logs, and wood waste.
• The particle size can be selected from a wide range of P100 to P32, with P63 typically used in boiler applications.
• We offer various knife options, including our specialized Multitool Rotor for challenging materials. 
• It is a more cost-effective choice in the long run. Robust, elegantly simple design and extensive maintainability make it durable.

See more:  Biomass Crusher Vertical

Download the buyer’s guide here and learn the differences between horizontal and vertical-fed machines!

Looking for a heavy-duty wood chipper? We have your back 

Contact us to hear more if you’re seeking a solution that balances high capacity with energy efficiency and longevity.

With over 170 units delivered globally and a strong presence in the Nordic countries, Chile, and Europe, our chippers have demonstrated their value in diverse industrial settings. 

Contact us here >>

Why prefer an on-site crusher?

Are you considering ways to handle and crush biomass with maximal efficiency? Then, you probably want to choose between a mobile crusher and a stationary crusher.

In addition to the machine’s features, it is essential to consider cost-effectiveness, environmental efficiency, and capacity. After all, you want to make an investment that offers long-term benefits and reliable operations.

See the comparison of a mobile crusher vs a stationary crusher and why we say an on-site crusher (aka stationary) is the better choice.

Mobile crusher or stationary crusher for biomass?

A mobile crusher and an on-site crusher often perform similar tasks. However, only one can dramatically reduce the use of fossil fuels, be more efficient in the long run, and handle significantly larger volumes of biomass.

The benefits of stationary crusher

Minimize emissions from transportation

Of course, the core feature of a mobile crusher is mobility. However, this also presents significant drawbacks: transporting a large machine requires a substantial amount of fuel, often fossil-based.

A mobile crusher needs to be transported to various biomass sites, requiring fuel and generating emissions. Using an on-site stationary crusher eliminates these transportation requirements and associated emissions.

An on-site stationary crusher can significantly lower the environmental impact of a mobile crusher by using a centralized facility and eliminating fuel-intensive transportation.

You can also minimize land disturbance by using an on-site crusher. Mobile crushers may need to operate in sensitive areas, such as forests or agricultural lands, which can lead to land disturbance compared to a single, centralized stationary facility.

Maximal capacity with robust construction

When it comes to capacity, on-site crushers can achieve significantly higher figures than mobile crushers. This is partly because a stationary crusher can be built more robustly and larger. Logistical requirements also limit the capacity of a mobile crusher.

The capacity of an on-site crusher can be adjusted and increased as per your requirements. Our crushers have the largest capacities in the world. For example, the capacity of the Saalasti Crush H crusher is selectable from 150 to 600 Im / h, depending on the material you use (P63).

“The capacity of the horizontal chipper is in a class of its own compared to mobile chippers. Especially in the winter season, we traditionally needed a lot of mobile chippers. Mobile chippers needed many trucks, which also consumed a lot of fossil fuels”, Lauri Heilala, Oulun Energia.

Improve the material flow with a stationary crusher

There are several reasons why stationary crushers can improve material handling compared to mobile crushers.

• By processing the biomass on-site, loose materials are not transported over long distances, which reduces transportation costs, emissions, and the risk of material degradation during transit.
• On-site crushing enables the processed biomass to be introduced more efficiently into downstream equipment, such as boilers. The crushing step allows the material to flow more smoothly, preventing potential bottlenecks and increasing the system’s overall throughput capacity.
• On-site crushing allows for better integration with other biomass processing steps, such as drying, screening, or pelletizing.
• Downstream operations can process the material more consistently, optimizing combustion or conversion processes.
•  Stationary crushers can also process various biomass materials, such as forestry residues, agricultural waste, and even mixed materials.
•  Stationary crusher also offers better potential for waste heat recovery.

Success story: the Oulun Energia bioenergy plant chose a solid crusher to reduce its use of fossil energy

The Finnish power company Oulun Energia selected a stationary crusher unit to enhance productivity at its bioenergy plant. This facility handles various materials such as forest industry by-products, chipped wood for energy production, wood waste, or recycled wood. The aim is to produce electricity and district heating and to replace fossil fuels.

The company saw many reasons to choose an on-site crusher instead of a mobile crusher. Capacity could be increased, seasonal fluctuations minimized, and, above all, fossil fuel use could be reduced. The on-site crusher does not require diesel but runs on electricity.

“The horizontal chipper is more cost-effective and energy-efficient than a mobile chipper. The payback period is reasonable, considering its high capacity and energy usage.” – Lauri Heilala, Oulun Energia.

Read the whole story.

Mobile crusher vs stationary crusher: Why prefer stationary 

• A stationary crusher offers higher capacity and a more robust construction.
• An on-site crusher has lower maintenance and operating costs in the long term (thanks for the full steel rotor and optimized knife shape and material for different biomasses).
• A stationary crusher can be more energy efficient by running it with electricity.
• With an on-site crusher, you can reduce the use of fossil fuels, as the machine does not need fuel such as diesel.
• Stationary crusher minimises seasonal variations in production.

>> Download a Crusher’s buyers guide here. 

Saalasti stationary crushers

We at Saalasti offer robust machines that are made to last for decades. With updates, the machines can handle different kinds of biomass materials and perform year after year with high efficiency.

The Saalasti Crush Horizontal is a high-capacity horizontal biomass crusher designed for on-site processing of all types of wood-based biomass, including impure materials.

• Features a robust construction and a Multitool ™ rotor that can handle various feedstocks, such as forest industry byproducts, logging residues, energy, and recycled wood.
• The Multitool ™ rotor makes utilizing a wide range of materials possible.
• The capacity is selectable from 150 to 600 I-m3 / h (P63), and the width of the crusher system can be up to 2.4 meters.
• Suitable for power plants, biomass terminals, and other facilities requiring high-throughput biomass processing.

Read more: Biomass Crusher Horizontal

Saalasti Crush Vertical

The Saalasti Crush V is the flagship model in Saalasti’s line of biomass crushers and has emerged as the preferred choice for numerous forestry operations.

Thanks to its robust and compact design, it has exceptional performance and reliability, making it the largest and most capable chipper in its class.

• Features a versatile rotor system that converts it between a crusher and a chipper. The rotor blades can be swapped out for crushing or chipping knives, depending on the biomass material that needs to be processed.
• Particle size P32–P100.
• Capacity 30–400 loose m3 per hour as needed. Depending on the material, the Saalasti Crush V’s capacity can be selected between 30 and 400 Loose m3 per hour (P63).

The flexible design enables the same machine to serve two different purposes simply by changing the blade type. Consequently, the Crush V can function as a wood crusher or a biomass chipper as required, making it a highly adaptable solution.

See all information: Biomass Crusher, Vertical

>> Learn more and get your free copy of Crusher’s buyers guide here. 

Do you want to hear more about on-site crushers?

Contact us to find out how we can help your company!

Can industrial effluent water produced by your process have a new life somewhere else in the process, instead of being treated as wastewater?

We are interested in finding new possibilities for effluent water treatment, especially from a circular economy perspective. Keep reading why finding new ways to treat effluent waters is essential!

Effluent water is a common by-product in many industries 

Effluent water is produced as a by-product in many industrial processes. It can originate from various industrial sectors, such as construction, chemical, and forestry. The composition of effluent water can vary greatly depending on the industry, the biomass being processed, and the processes involved.

We specialize in dealing with effluent from compressing wet wood or other fibrous biomass to dry it.

Industrial effluent may contain various substances such as chemicals, heavy metals, organic compounds, solids, and microorganisms. The liquid is typically enriched with phosphorus, nitrogen, potassium, and zinc. It may also contain chlorides, sulfates, nitrates, and hydrocarbon compounds. The substances require purification, but some can be beneficial, like phosphorous in agricultural fertilizer.

COD and BOD are essential values for effluent water quality

Key indicators of the content in industrial effluent are COD (Chemical Oxygen Demand) and BOD (Biological Oxygen Demand), which demonstrate water quality. Both levels must be reduced before effluent can be reused or controllably discharged into the environment.

The COD measurement indicates how much oxygen is needed to chemically decompose the organic substances in the water. This test provides an overview of the total amount of organic material in the water. An advantage of COD is its faster testing time compared to BOD, as the results can be achieved in a couple of hours compared to days.

The BOD value measures the quantity of organic matter in water that can consume oxygen during decomposition. If the level of organic material in water is high, resulting in a high BOD value, microorganisms can consume a large amount of oxygen to break down these substances. This can lead to a situation where there is not enough oxygen left for other aquatic life, such as fish, which can cause environmental problems.

COD values are higher than BOD as COD includes all substances that can be chemically oxidized, whereas BOD only measures substances that can be broken down biologically. 

We are able to extract an effluent water sample from the biomass processed by our customers, and we obtain laboratory analyses from a third party. Therefore, through us, you receive a comprehensive and customized picture of the composition of the material to be pressed.

Why should we look for new ways to use effluent water?

Treating and managing industrial effluent is crucial for protecting the environment and promoting sustainable development. Once treated effectively, the effluent can be safely discharged into nature or reused in industrial processes.

The question we should ask is: why not find new solutions? When handled correctly, effluent should not be seen as waste but as a valuable resource.

Why effluent water should be utilized?

• To transform by-products into valuable resources.
• To support the circular economy and give a new life to materials once considered waste.
• To meet the environmental regulations, where there’s a push for better water protection and circular economy practices become more manageable.

Where could effluent water be used?

Depending on the components and composition of the effluent, it can be repurposed for various uses. Here are a few examples, some of which are already feasible and others that could be possible in the future.

Fertilizer: Effluent water containing nutrients like nitrogen and phosphorus can be processed to recover them and used as fertilizer.

Irrigation: Treated press water can be used for irrigation if it’s safe for plants and soil.

Re-use: In industrial processes like paper and pulp production, effluent water can be treated and reused to conserve water.

Energy production: Effluent water containing organic material can be used for biogas generation through anaerobic treatment.

As a raw material in the food industry: Press water generated from the pressing of fruit juices or oils can be utilized as an ingredient.

In all cases, it is crucial to ensure that effluent is treated, analyzed, and appropriately purified before it is utilized.

Read also:  What does sustainability mean to Saalasti?

Are you looking for a partner to find new solutions for effluent treatment?

“We are eager to innovate solutions that can derive significant added value from effluent.”

If your company operates in an industry where effluent treatment is a current issue, do not hesitate to get in touch! 

“We are also looking for a partner with experience in wastewater treatment who could innovate with us to develop an effective solution for cleaning industrial effluent water.”

With decades of experience in mechanical dewatering solutions that lead the market in their field, we are happy to discuss more about new solutions for industrial effluent water. 

Contact us!

Read Saalasti customer stories here.

How can you ensure your machine creates the most value for you in changing conditions? Are you planning to increase capacity or switch to other biomass?

Updating and upgrading machines allows your facility to operate efficiently in varying conditions without requiring new equipment purchases.

Saalasti machines are renowned for their longevity, with some still in operation since the 1980s. This is largely due to professional maintenance and regular updates.

Discover the advantages of upgrading or updating your Saalasti machine for improved operations and performance. Keep scrolling to learn more.

Machine updates are a crucial part of maintaining machine performance and longevity as part of professional maintenance.

Machine upgrades will increase performance and productivity 

Upgrading your machine is a good idea when:

• You want to increase your facility’s capacity, performance or other key production indicator. For instance, replacing worn capital components with upgraded versions will improve your machine’s performance significantly.
• There is a need to upgrade the machine to handle new types of biomass. For example, you need to transition from clean roundwood to more dirty and easily available biomass types. 
• If certain machine parts are worn or damaged, replacing them with new ones may be necessary to achieve maximum efficiency in machine operation.
• You want to improve the machine’s energy efficiency. Upgrading to more energy-efficient components can save energy and reduce operating costs.

“The wood brought down by the storm was not fit for paper production, but it could be used for energy production/used as energy in biomass power plants. Saalasti adapted the Saalasti stump crusher for processing round wood. “ Read more.

Case: Upgrading bark presses to improve performance for years ahead

Numerous performance upgrades have been implemented on Saalasti Bark Press machines over the years, and currently during the recent year’s significant updates to the pressing process has been implemented yielding higher dry solid content and more stable output from the machines. Close to a dozen of press units are equipped with the latest performance updates and more is still to come. We install these upgrades on both new and older machines.

The machines have been efficiently handling materials such as pine and spruce bark and have served the customer’s facility well for years. Thanks to our continuous machine updates, their performance has significantly improved.

Performance upgrades enhance the machine’s capabilities for up to decades. With careful component selection, we ensure smooth operation, and the machine is also easy to optimize and update as needed over the years. This enables our customers to fully benefit from the system update.

What types of machine upgrades does Saalasti offer?

We can upgrade our machines based on your facility’s needs and the processed biomass types.

Examples of typical upgrades: 

• Performance upgrades.
• Wear resistance upgrades and improvements.
• Process optimization.
• Second-hand machine rebuilds and upgrades. 

Refurbishment and rebuild services are provided by all of our service centres worldwide, some even manufacturers of new parts as well. Refurbishment of certain parts is environmentally and economically wise. By using Saalasti OEM services, we can guarantee top quality and OEM specifications on refurbished parts.

Why should continuous maintenance not be forgotten?

The performance of machines depends not only on updates but also on regular and timely maintenance, which is crucial for both performance and cost savings.

The benefits of expert maintenance service:

• Ensure that the machines operate efficiently and cost-effectively throughout the year without being affected by seasonal variations.
• Get informed of maintenance needs well in advance.
• Avoid unexpected equipment failure and production interruptions through proactive maintenance.
• Regular maintenance prevents safety issues, protecting machine users.

OEM maintenance services ensure safe operation and compliance with regulations.

When you opt for OEM manufacturer service, you can rest assured that you will receive the best possible results. Our team of experts has an in-depth understanding of our machines and extensive knowledge of their design, operation, and maintenance requirements. 

We provide comprehensive maintenance and lifecycle services to customers worldwide. Learn more about our lifecycle services and OEM spare parts.

Read also: How to maintain the maximal performance of Saalasti machine? Maintenance and lifecycle services at your service

Why should you choose Saalasti as a service and maintenance partner? 

• You will receive service from the original equipment manufacturer (OEM), a leading company in the biomass machine industry.
• We offer OEM parts designed and manufactured specifically for the machine. The high-quality parts ensure efficient and reliable machine performance. Using third-party parts can compromise quality and increase the risk of breakdowns. 
• Ensure your machine performs at its best and maintains its functionality today and in the coming decades.
• We offer locally tailored services to meet your specific needs.
• Many of our long-term customers can attest to their high satisfaction levels.
• You can obtain accurate documentation that provides a detailed record of the machine’s maintenance history.
• We keep a close eye on industry requirements and update our machinery accordingly. You’ll gain access to these benefits during updates.

Contact us to learn about machine upgrades and other solutions that can extend the life and enhance the performance of your Saalasti machine.

Replacing peat in growing media is becoming increasingly important for the sake of the climate and the conservation of ecosystems. In Europe, there is a growing urge to move away from peat, which has opened up new opportunities for finding alternatives. 

Wood fiber is one of the most promising sustainable alternatives that can be used to replace peat in growing media.

At Saalasti, we naturally have a keen interest in exploring how wood can be used in new and sustainable ways. We are a market leader in biomass processing machinery and offer solutions such as mechanical drying, particle size reduction, and grinding.

Wood fiber can be a sustainable substitute for peat 

Peat has been the primary choice for growing media in Europe for many years. However, in the future, the role of peat will be smaller due to its non-renewable nature and classification as a fossil fuel. Peat extraction can have harmful effects on the environment, including habitat destruction, biodiversity loss, and the release of carbon dioxide into the atmosphere.

The use of wood fiber as a growing medium is not a new concept, but recently there has been an increased need for alternative fibers. Wood fiber cannot entirely replace peat but can be used to supplement growing media with more sustainable material and reduce the reliance on peat.

Benefits of wood fiber in growing media: 

• Renewable material that can be obtained from sustainably managed forests.
• Wood fibers can enhance the water-holding capacity of growing media, helping to provide a more consistent moisture level for plant roots.
• When properly processed, wood fiber offers a stable and high-quality material.

The quality of the wood fiber matters 

The quality of the material is crucial when talking about using wood fiber in growing media. Poor-quality and impure wood fiber can carry pathogens and harmful substances, and the biodegradability of the fiber may be too rapid, which is not a good thing for growing abilities. 

To ensure that wood fiber meets quality requirements, an effective way is to obtain RHP certification. RHP certification guarantees that growing media meets strict quality control standards such as particle size, nutrient content, and water-holding capacity. It also assures safety and that the growing media is free from harmful substances, contaminants, and plant pathogens.

At Saalasti, we join the process of wood fiber by reducing the particle size and pressing moisture.

These steps are crucial in achieving a consistent and RHP approved quality of the material. By reducing the particle size, we improve uniformity, and by removing moisture, we enhance the overall quality of the wood fiber.

Why is it important to prioritize water removal from wood fiber?

Wood fiber is often processed through grinding, where the size of the wood pieces is reduced, and the fibers separate from each other. 

But how could the process be improved if the wood fiber were as dry and consistent as possible before grinding? 

Mechanical water removal before grinding offers many advantages, as it ensures optimal grinding conditions, resulting in better performance and energy savings in the process. We believe that it is at least one of the key factors to enhance the processing of wood fiber.

The benefits of mechanical high-pressure dewatering and grinding (Saalasti biogrowth system)

• • Improved grinding efficiency due to mechanical high-pressure stage. As the excess moisture has been removed, it enhances the grinding process.
  • Based on our experiences, the yield of wood fiber is significantly better when it is compressed before the grinding process.
  • Improved energy efficiency in the grinding process due to mechanical high-pressure, as there’s no need for the thermal process. 
  • The process can remove some of the harmful substances from the wood that may negatively affect plant growth and volatilize some of the harmful wood compounds into the air by pressure.
  • Improved size control. The size of the wood pieces can be controlled, resulting in a material that has a more consistent and uniform particle size.
  • Improved quality; for example, the amount of fibrous material and the level of coarseness can be adjusted.
  • Possible to mix fiber and other materials, like peat, through the press.
  • Very low operating and maintenance costs.

Read also: Dewatering press with a great energy saving potential: What are the benefits of mechanical drying?

Saalasti solutions that can be applied to wood fiber processing

• Saalasti Press “Hippo” is a new-generation dewatering press with a huge water-removal capacity: it can remove even more than 50% of the water content. The press is suitable for many fiber-based plant materials.
• Saalasti Bark Press SP 1620 is the most popular bark press on the market, trusted by market-leading companies worldwide.
• See all our solutions here.

Contact us to hear more 

Do you want to hear more about how our solutions can help with wood fiber used in growing media? Contact us and let’s discuss more. 

We have more than 40 years of experience in biomass processing and we are constantly looking for new applications.

Read next: Biomass processing: Master the performance with the right solutions

How can a high-quality dewatering press improve biomass drying? And why is it wise to prioritize mechanical drying with minimal thermal drying for higher energy savings?

Learn how an effective dewatering press can make your process smoother and be both more economical and sustainable. 

Saalasti is a pioneer in the drying of biomass with decades of experience. The new dewatering press Hippo is a next-generation mechanical dryer that has unique technology.

The dewatering press is the industry standard for biomass drying

In the biomass industry, dewatering presses are a prime example of efficient mechanical drying. They work by applying mechanical force to materials, effectively squeezing out moisture. This technology allows for efficient moisture removal while maintaining the material’s integrity.

The dewatering press can be applied to many fiber-based biomass material operators, such as:

• Pellet plants, for both wood chips and sawdust.
• Pulp and paper mills. 
• Power plants.
• Panel board operators.

Saalasti’s dewatering presses can operate with any fiber-based biomass material. The best results are when the machine is tested and tailored for the material, which we do in the Saalasti test laboratory.

Mechanical drying vs thermal drying? 

The question of the relationship between mechanical and thermal drying often arises in biomass drying. Both methods, mechanical and thermal drying, are necessary, but by making smart choices, the overall process can become more efficient and result in higher-quality biomass.

In general, it is recommended to minimize the use of thermal drying to maximize energy savings.

Thermal drying utilizes heat energy to reduce the moisture content of biomass materials, while mechanical drying, as known, is based on forces such as compression. 

Mechanical drying provides several advantages over thermal drying. The main advantage is evident in the lower energy consumption of mechanical drying.

In mechanical drying, the energy consumption is typically around 20-30 kWh per ton, while thermal drying can be as high as 700-1000 kWh per ton. 

When comparing cubic meters of water removal,

• the energy consumption for mechanical drying is estimated to be around 30-50 kWh. 
• Thermal drying ranges from 700-1000 kWh per cubic meter.

It’s important to understand that effective mechanical water removal can also impact the efficiency of thermal drying. Even though mechanical drying may not eliminate the need for thermal drying entirely, but it greatly reduces the energy required.

As a result, mechanical drying not only helps to remove water more effectively but also improves the overall drying process, making thermal drying more efficient. By reducing the amount of thermal drying, the remaining thermal drying becomes more cost-effective. 

Mechanical drying also improves the thermal drying efficiency.

Mechanical drying advantages 

• Enables greater energy savings, which positively impacts the entire process.
• The operating and investment costs are likely to be lower with mechanical drying. They require less energy input, and maintenance and equipment costs can be relatively lower.

• It helps maintain high-quality biomass throughout the process. The seasonal variations of the material quality can be removed as the moisture content stays steady.

The new-generation dewatering press reduces moisture content drastically

The Saalasti High-Pressure Press 1803 represents an advanced mechanical dewatering solution with a dramatic ability to remove water. 

During the process with the Saalasti dewatering press Hippo, wood chips are partly crushed, resulting in an increased evaporation surface area. 

As the press can reduce the moisture content of the material by up to 55 %, the remaining thermal drying process requires less heat energy. Pre-crushed materials also reduce wear in hammer mills and pellet presses.

Hippo dewatering press makes not only the dewatering but also the rest of the process easier.

• The drying process is very efficient. The machine can remove up to half of the water and greatly enhance the quality of the material.
• The quality of the material will be even. 
• Reduces energy use and thus carbon footprint.
• The particle size can be optimized and optimally homogenous.
• Reduces blue haze and VOC releases during the squeezing process.
• It can reduce the use of fossil fuels in heating.

The outcome of the dewatering press is material that is 40% moist, whereas the typical situation would be 55-60%.

Read more: Saalasti Hippo dewatering press

Thermal dryer vs. Saalasti dewatering press

Energy use of thermal dryer vs. Saalasti dewatering press

Success story: Dewatering press reduces even 55 % of the water content

Saalasti Hippo dewatering press was essential to the success of van Roje, a German company that produces FSC-certified wood pellets. By using the Hippo, van Roje was able to increase its production capacity from 60 to 90 tonnes without needing extra burning systems or more heat. The dewatering press significantly reduced the cost of production per tonne and saved a lot of energy.

 “There was no need to invest in energy production or an additional combustion system. Otherwise, we would have needed a bigger belt dryer.” – Gerhard Hauschulte, the Managing Director of van Roje.

Read the whole story: Pellet production success Story: Maximal production volume with the same amount of heat

Want to know more about market-leading dewatering presses? 

Contact us to discuss more about your needs for biomass dewatering. We offer comprehensive machine installations and upgrades with over 40 years of experience. You can also get maintenance, lifecycle services, and spare parts from us all under one roof.

Contact us >> 

Read next: Biomass processing: Master the performance with the right solutions

Biomass processing has become an increasingly hot topic lately as industries aim to reduce their carbon footprint, improve energy self-sufficiency and reduce the use of fossil fuels.

However, to get the full potential of biomass requires more than just the availability of the material. Your plant needs the right processing and machinery specifically designed for your biomass to gain the best benefits. 

Keep reading to learn about the best practices in biomass processing and the things that should be considered before investing in a biomass processing machine.

As the market leader in biomass processing solutions, we have a long history of providing solutions for fiber-based biomass materials. Our biomass crushers and chippers are trusted in different parts of the world.

Biomass processing means a shift away from fossil fuels

The global energy crisis has accelerated the demand and need for alternative energy sources. The prices of fossil fuels fluctuate, their availability is uncertain, and relying on them for the future is not sustainable.

Recently, many industries have started embracing biomass processing as a complement or alternative to traditional energy sources. This shift in trend reflects the growing recognition of biomass as a valuable and flexible fuel in various sectors.

Diversification of the energy mix improves your plant’s energy security. You do not need to rely only on a single energy source, and you can control the production chain better. 

With the energy crisis, there is also a question of what kind of energy your processing line use. Mobile crushers often rely on fossil fuels such as diesel, which increases overall operational costs. By utilizing an on-site electrical crusher, you can reduce the use of fossil fuels also.

How to get more out of biomass processing: five things to consider before machine investment or updating

1. Can the machine handle various kinds of biomasses? 

Why operate with only one biomass if your plant can process many? Your plant can get more out of your fuel mix when one machine solution can process a broader range of biomass. 

This increases the flexibility of your production as you can switch to a more readily available or cost-effective fuel source.

Saalasti machines can be tailored and optimized according to the specific biomass being used. This allows you to upgrade the old system into a highly adaptable unit.

Our machines are suitable for many fiber-based materials, such as:

• Pine, birch
• Eucalyptus, palm fronds (basically all wood species!)
• Sugarcane, vineyard waste
• Logging residues and urban garden waste
• Stumps
• Sawmill residues, sawdust
• Pellets
• And many, many other biomass types. Contact us to hear more!

The machines are commonly used in fuel terminals, power plants, sawmills, pulp mills, and similar facilities.

Read a case story: A biomass power plant got a tailored machine adaptation to changed needs after a storm cleared the woods. Saalasti was able to adapt the crusher to be suitable for the processing of round wood that was brought down by the storm. 

2. Does the capacity flex according to your needs?

A high-capacity biomass machine allows your plant to adapt to changing demands and market conditions. You have the flexibility to adjust the processing capacity according to biomass materials’ availability and market demand fluctuations.

With Saalasti machines, your plant is ready to scale up performance easily. For instance, you can fill your power plant silos or storage facilities during daytime shifts, eliminating the need for evening or weekend work shifts.

Combined with automation, scaling up also offers the possibility to save costs. A larger capacity allows you to process a higher volume of biomass within a shorter timeframe. 

Read a customer story: A significant capacity increase in the pelletizing plant from 65 tonnes per hour to over 100 tonnes per hour. 

3. What is the expected lifecycle of the machine?

Biomass processing machines are investments that are expected to perform year after year. Thus it is essential to familiarize yourself with its maintenance options that ensure the lifespan.

The reasons why Saalasti machines are long-lasting:

• Robust construction that is capable of handling large capacities.
• Maintenance and optimization possibilities. Our machines can be updated and optimized for new materials and different particle sizes.
• Compared to many other solutions, our machines have fewer blades, which means equally efficient operation at lower costs. In addition, our blade replacement is completed in less than an hour.
• Safety mechanisms prevent stones and impurities from entering the machine, reducing the need for maintenance.

4. How does the process consider energy efficiency?

Biomass is inherently renewable and even circular energy, but energy can be wasted in its production if the right choices are not made.

Pay attention to these aspects of energy efficiency in biomass processing:

• Durability and construction of the machines.
• Use of automation and optimization possibilities.
• Power sources for the machines: electricity, fossil fuels, or other energy? Mobile crushers require constant fuel, unlike machines that are placed on-site.
• Regular maintenance ensures the best performance of the machines.
• Logistics and material density. When the material is as compact as possible, you can reduce its carbon footprint and minimize the fossil fuel footprint.

The power consumption of Saalasti machines is aimed to be as low as possible per produced ton, as robust machines efficiently handle large capacities. In addition, energy efficiency is improved by a closed rotor design.

Additionally, a stationary machine is relatively cost- and energy-efficient compared to a mobile crusher. 

5. Does the processing also improve the quality of the biomass?

Not just about speed and capacity but also continuous quality control that maintains high performance in biomass processing. This ensures a consistent calorific value, improves process efficiency, and enhances material productivity.

Things that affect biomass quality:

Particle size control. Controlling the particle size improves material consistency, leading to better utilization efficiency. Irregular or oversized particles can result in uneven combustion and reduced energy output.

Moisture content. High moisture content can lead to incomplete combustion and decreased energy output—proper drying or conditioning of biomass before processing is essential.

Read also: Mechanical dewatering with Saalasti solutions

Minimizing impurities: Biomass can contain impurities such as stones that can damage equipment and impact the quality of the end product. 

Understanding the specific characteristics of your material: There is no one-size-fits-all biomass, meaning machine optimisations are needed. At Saalasti, we ensure material suitability through our test laboratory.

Read also: A solution tailored for eucalyptus. Saalasti’s solution has improved the quality of processed wood, producing clean-cut particles with minimal “fluffy” texture that could compromise quality. 

Through quality control, you can minimize seasonal variations in biomass quality.

Get to know market-leading biomass processing machines

Solutions for the reduction of particle size: 

Saalasti Crush H: A powerful horizontal on-site crusher designed for high-capacity operations. Equipped with a cutter bar, it effortlessly handles all types of wood-based biomass. The machines are trusted by power plants and biomass terminals worldwide. See also vertical biomass crushers Saalasti Crush V.

Saalasti Chipper H: A horizontal feed biomass chipper designed for chipping and crushing. The world’s first high-capacity stationary chipper for on-site use is used in various high-capacity facilities, including biomass terminals, power plants, and pellet factories.

See also: Reduction of particle size

Contact us to get the most out of biomass processing

Get in touch, and let’s discuss your plant’s needs. Our clients range from biomass power plants to other industries that use biomass on an industrial scale – contact us to hear more.

We are continuously developing our services, and in addition to delivering technological solutions, we can also support your biomass production with tailored solutions. Ask for more!

Read next: Biochar production: The benefits of high-performing biomass pre-processing

Saalasti solutions are the market leaders for biomass power plants, where there is a need to improve the processes, capacity, and quality of the material.

We are the market-leading partner for companies that handle different kinds of biomass. Read our customer cases where our solutions are successfully used in biomass power plants.

Solutions for biomass power plants: The benefits of Saalasti partnership 

Our machines offer many benefits, such as a long lifespan, tremendous capacity, and the ability to process challenging biomasses, such as round logs, cargo pallets, bundles, and pre-crushed stumps. 

Successful change from coal boilers to biomass boilers 

Company: E.ON Centrale de Provence

Location: Gardanne, France 

The German E.ON, one of the largest energy companies in the world, uses Saalasti Feeders and Chippers in the power plant in Gardanne. In 2012, the company decided to shut the old coal boiler down and convert one of their existing coal boilers to a 600MWth wood-based biomass boiler. Before the transformation, the coal power plant was 2500MW. 

The make the enormous scales, there was a need for big capacity for biomass processing. The biomass power plant would consume wood about 900 000 tonnes per year, both imported and locally. 

The enormous scale required a large capacity biomass processing solutions.

To ensure a steady supply of biomass fuel to the boiler, E.ON started to construct a chipping platform close to the boiler’s location. E.ON opted to install a Saalasti Chipper 1218H, which can process up to 100 tons of biomass per hour. This translates to an impressive yearly capacity of approximately 300,000 tons.

Saaasti chipper is used to transform various woody biomass forms into combustible forms. This includes everything from round logs to reclaimed wood from demolition sites, cargo pallets, bundles, and pre-crushed stumps. The chipping process reduces the material to size P63. 

>> See the whole story here (pdf). 

Biomass power plants got tailored machine adaptation to rapidly changed needs 

Plant: Dalkia Atlantique, Smurfit Kappa Comptoir du Pin Paper Mill 

Location: Biganos, France 

Forest industry company Dalkia Atlantique operates a biomass power plant, where there was planned to start a new era in paper making with the help of stump retrieval with a special Saalasti stump processor.  To meet the annual demand of 500,000 tons, the plant planned to utilize 170,000 tons of stumps collected from the Landes Gascogne forest.

But then the cyclone “Klaus” changed plans overnight: In just one day, a massive 39 million cubic meters of forest were cleared – a staggering four times more than the typical annual harvesting amount.

The wood brought down by the storm was not fit for paper production, but it could be used for energy use in biomass power plants. Saalasti was able to adapt the Saalasti stump crusher to be suitable for the processing of round wood. 

The new installation of Saalasti Chipper 1218H made it possible to produce  150 tons of energy chips per hour from various sources such as round logs, forest residue bundles, and pre-crushed stumps. Later the specialized Saalasti PreCrush stump processor was added to the processing line.

It is notable that the PreCrush can remove up to 20% of sand from stumps, reducing wear and tear on equipment at every stage of the process. 

The Saalasti solution has now separate loading areas for both stumps and round wood.

>> See the technical details here (pdf). 

A massive improvement in the production of renewable energy with noise emission regulations

Company: Dalkia 

Location: Lens, France 

Dalkia, a subsidiary of French utility company EDF,  invested in a new 22MWth biomass-fired power plant in Northern France. Thanks to Saalasti’s solutions, the power plant generates approximately 6.2 MWe of electric power. It is recognized as part of the French Energy Regulation Commission’s CRE3 program, which aims to accelerate the adoption of renewable energy on a larger scale.

Dalkia installed a high-capacity, on-site biomass processor, which secured the continuous biomass supply and massive capacities. The solution was to install Saalasti Chipper 1212H, which can process 70 tonnes per hour of all kinds of biomass, from pre-crushed stumps to trees and logs.

The solution is optimized for long dimensional woody biomass.

The was also a need for noise reduction, as the site locates near a residential area and nature reserve. Saalasti’s solution was to install a special long noise reduction tunnel, which makes the solution more suitable for a delicate environment.

>> See the technical details here (pdf). 

A solution tailored for eucalyptus bark in biomass power plant 

Company: Alvarez Forestal S.A. 

Location: Reocin, Cantabria, Spain

Forestry company Alvarez Forestal specializes in processing fast-growing species such as Eucalyptus globulus and Pinus radiata. Since 2012 the company has operated in a biomass-fired power plant, which serves its plant and also the grid. The barks and branches are loaded on the Saalasti Feeder in the power plant and fed into Saalasti Chipper 1212H.

Eucalyptus is a great species for pulp production with good fiber characteristics, but it must also be processed specially. 

 One of the major challenges in processing eucalyptus is the high level of embedded sand. The sand is a result of the tree’s rapid growth in silt-rich soil and can cause significant wear and tear on machinery. Additionally, the bark of the eucalyptus tree is highly resistant to cutting forces, presenting an additional challenge in the processing of this type of wood.

Saalasti’s solution has improved the processing of eucalyptus drastically. With Saalasti Chipper 1212H, the bark is processed clean-cut particles with minimal “fluffy” texture that could weaken the quality.   

Saalasti’s solutions help to process demanding eucalyptus biomass with great energy value.

>> Read the main numbers of the solution here (pdf). 

A huge capacity rise in the pelletizing plant 

Company: Biosyl

Location: Cosne-sur-Loire, France 

Biosyl, a French leader in renewable biomass energy, converts wood waste and debris into low-carbon emission energy, in the form of wood pellets. In the Loire valley pelletizing plant, Biosyl had a remarkable plan to raise the capacity of pellet production. At first, the processing capacity was 65 tonnes per hour in the particle size P32, but the aim was lifted to over 100 tonnes per hour. 

One of the key factors that led to the selection of Saalasti technology was its ability to increase the processing power of biomass. The power plant was installed with 2 X 355 kW motors (total 710 kW), with the plan to upgrade to 2 X 500 kW motors in the future. This upgrade will increase the plant’s biomass processing capacity to a total of 100 tons per hour.

The capacity raise was possible with Saalasti’s biomass technology.

>> See the whole story (pdf).

More efficient solution than mobile crushers and chippers

Company: Moulin TP

Location: Monistrol, France 

Moulin TP processes biomass for combustion purposes, and the plant is one of the biggest woody biomass producers in the area. Before the year 2013, Moulin TP was relying on mobile solutions in biomass production in the Monistro sur Loire plant. 

Since the change to Saalasti’s solutions, Moulin TP has been able to drastically raise the capacity and improve the processes. 

With the help of Saalasti machines, Moulin TP terminal could produce 120,000 tonnes of biomass per year and serve 17 customers. As demand grows, the platform can double its capacity to 250,000 tons per year. 

>> Read more about the case here.

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