saalasti, tekijä sivustolla Saalasti

Horizontal chipper delivered to biopower plant will ease the shift away from fossil fuels

Saalasti delivered a horizontal chipper to Oulun Energia’s Laanila biopower plant in Oulu, Finland. The chipper will have a crucial role, as the CHP plant aims to increase the use of energy wood in producing fuel for a bioenergy plant while reducing the use of fossil fuels.

Horizontal chipper helps to raise the capacity of biopower plant

Laanila’s biopower facility focuses on modern energy production by efficiently generating electricity, district heating, and process steam. The plant plays an essential role in carbon-neutral energy production, towards which Oulun Energia is determinedly moving.

The facility using cutting-edge technology was opened in 2020. The biopower plant has a flexible boiler that can adjust to different fuel types and proportions, allowing for integration with nearby bioeconomy.

Laanila power plant will phase out the use of peat and shift to wood as the primary fuel source. The types of wood used in the process can be, by-products of the forest industry (bark, sawdust) and pruned logging residue, unpruned energy wood, logging slash, or recycled wood.

Investing in an efficient on-site chipper was necessary to increase wood chipping capacity.

“The horizontal chipper is an important strategic investment that allows us to improve the reliability of chip deliveries, react to peak consumption periods, and reduce seasonal variations in production,” says Lauri Heilala, Director of Fuel Sourcing in Oulun Energia.

From now on, electric horizontal chippers will replace fossil fuel-based operations.

Chipping is performed with an electric-powered stationary chipper instead of a fossil-fuel powered mobile machine, which is essential for achieving carbon neutrality targets.

Photo by Oulun Energia.

More efficiency and lower usage of fossil fuels compared to a mobile crusher

Oulun Energia weighed the advantages of an on-site chipper and mobile crushers in the procurement process. The horizontal chipper was found to have many winning features that would secure resource needs.

The on-site horizontal chipper offers high capacity and a clear production chain.

“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”, Heilala states.

“Additionally, when the on-site chipper is on our premises, the production chain is more manageable”, he adds.

“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.“

Besides higher capacity, energy used by the horizontal chipper is also more environmentally friendly, as the need for fossil energy is minimized.

“We can use the on-site chipper with our electricity, which is both cost-effective and better for the climate than a mobile chipper running on fossil fuels”, Heilala says.

Starting the new project: Saalasti’s Project Manager Henri Kuismin, Oulun Energia’s Director of Fuel Sourcing Lauri Heilala and Project Engineer Samuli Korpela. Photo by Oulun Energia.

Smooth communication throughout the delivery process

Oulun Energia is pleased with the turnkey delivery process and the smooth communication with Saalasti professionals.

Saalasti was chosen as a partner due to both their impressive product range and their experience.

“Saalasti listened carefully to our needs and tailored their solutions accordingly, making the process easy. Also, in these times, collaborating with a domestic company is always a plus”, Heilala tells.

The machine is scheduled to be fully operational in 2024.

“We look forward to getting the horizontal chipper in operation.” Heilala ends.

Oulun Energia

Operating in energy production and heat and electricity network services in the Oulu area.
The city of Oulu is the owner of the company, which was founded back in 1889.
Aiming to carbon-neutral energy production by 2030.

Improve the performance of your machine with an upgrade

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.

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.

We had our climate impacts calculated: Saalasti’s carbon footprint and Hippo’s handprint

Our commitment to environmental responsibility extends to our own operations, and thus, it was only natural for us to assess our climate impacts based on calculations. Our primary focus in our operations is to provide our customers with technology services that support the transition to a low-carbon future.

We calculated Saalasti’s organizational carbon footprint, considering our own, scope 1 2 emissions, and emissions from our value chain (scope 3).

Additionally, we conducted a handprint study of Saalasti’s High-Pressure Hippo. It was essential for us to understand the positive climate impacts our solutions can offer.

Compared to the prevailing method of drying biomass, the Hippo machine saves greenhouse gas emissions.

The studies were conducted by a Finnish environmental specialist, UseLess Company, whose speciality lies in life cycle assessment (LCA), including carbon footprint calculations.

How was the carbon footprint calculated?

The carbon footprint study was conducted using the GHG (Greenhouse Gas) protocol, the most used standard for calculating organizational carbon footprint.

This standard helps evaluate an organization’s climate impacts in a reporting year.

In GHG protocol, greenhouse gas emissions are divided into three categories called scopes:

Scope 1 emissions are those directly generated by a company’s operations, such as facility and vehicle use.
Scope 2 emissions consist of indirect emissions of energy production, primarily from electricity and heating.
Scope 3 emissions are indirect emissions that occur in a reporting company’s value chain and are for example, related to production, transportation, and use of sold products. These emissions are not directly under the organization’s control but can be influenced through partnership choices and customer guidelines.

Scope 3 emissions are further categorized into upstream and downstream emissions:

Upstream emissions pertain to the supply chain and early stages of process, including emissions from the production of products and services.
Downstream emissions occur after a product has left the customer’s premises. They are associated with product usage, distribution, and the end phases.

Saalasti Finland Oy carbon footprint 2022:

The total carbon footprint of the company was 22 512 tCO2e (carbon dioxide equivalent)

The top three emissions sources were:

88.1% Use of sold products
10.0% Purchased goods & services
0.44% Business travel

Compared to other CO2 footprints:

Average Finn 10 tCO2e (Sitra, 2018)
City of Helsinki 2 349 000tCO2e (HSY 2021)
Finland 45 816 000 tCO2e (Tilastokeskus 2022)

Showing the carbon footprint without the category of “use of sold products” is important to provide a comprehensive view. When the largest emitter of emissions has been removed, the relationships between other categories become more distinct.

And without taking into account the category of use of sold products, the results are:

The total carbon footprint of Saalasti company: 2671 tCO2e.

Top emission sources:

84.5% purchased goods & services
3.7% business travel
3.1% upstream leased assets.

But what should be considered when we talk about the largest portion of the carbon footprint, which is the use of sold products (machines) delivered to our customers?

Even though the products we produce reduce significant amounts of energy, it is important to note that reducing emissions in the value chain is not solely within our control. However, emissions from the energy sector are expected to decrease globally in the coming years, reducing the climate impact of this category.

As our CEO Petteri Korpioja puts it:

“Our most significant climate impact lies in our ability to help our customers reduce their emissions. Also, our R&D people are constantly developing our products to find even more energy-efficient solutions for our customers.”

“Compared to other players in the industry, our solutions are remarkably energy-efficient. Therefore, our solutions should be compared to other players, as looking at the carbon footprint alone doesn’t tell the whole story.”

The results for Hippo

The Saalasti High-Pressure Press 1803, also known as Hippo, is a high-pressure press that relies on mechanical dewatering capabilities for its efficiency. Mechanical drying reduces the moisture content in biomass and significantly increases its calorific value.

Hippo’s efficient drying process significantly reduces the moisture content of biomass, leading to significant energy savings. This can be achieved when auxiliary fuel (often fossil-based) can be reduced or eliminated during the drying process. When the material is drier, its heating value is higher, and less biomass is needed.

Carbon footprint of Hippo, total

Carbon footprint of Hippo, total cradle-to-customer

Customer location	Product manufacturing [kgCO2e]	Transportation of the components to Saalasti [kgCO2e]	Transportation, product to customers [kgCO2e]	Total [kgCO2e]
Canada	76 991	3071	10 764	90 826
Sweden	76 991	3071	676	80 738
Chile	76 991	3071	16325	96 387
Portugal	76 991	3071	10 447	90 509
Spain	76 991	3071	9 610	89 672
France	76 991	3071	7 117	87 179

The carbon footprint of the product manufacturing is the same, regardless of which country the machine will be delivered.
Transportation components to Saalasti are also the same, 3 071 kgCO2e.
Thus, variation occurred in transportation due to different locations and transportation methods. Transportation emissions varied from Sweden’s 676 kgCO2e to Chile’s 16 325 kgCO2e.

Emissions from component production and transportation are the same despite the customer location because production occurs in Finland, and differences occur when the device is transported to the customer. Naturally, the number of transportation kilometres and mode of transportation affects transportation emissions.

And what about carbon handprint?

It’s not just about negative climate impacts; the carbon handprint is significant regarding climate effects. Calculating the carbon handprint reveals positive climate effects in contrast to prevailing practices.

A carbon handprint represents the reduction of the carbon footprints of others.

The carbon handprint can be considered the counterpart to the carbon footprint, representing the reduction of carbon emissions in the value chain resulting from specific actions of a reporting company.

The carbon handprint is calculated by comparing the climate impacts of two similar products or services. It is determined by subtracting the carbon footprint of a company’s product from the baseline carbon footprint.

The calculation of carbon handprint is based on the ISO 14067 standard.

After establishing the baseline, the reduction in emissions needs to be quantified using standardised measurement and verification processes. Read more about the process of handprint calculation on VTT.

Handprint calculated: How does Hippo compare with other solutions in biomass drying?

In Saalasti’s case, the carbon footprint of the Hippo machine was compared to two other solutions in the pulp mill case.

In baseline situation 1, there was a thermal dryer on the site before the decision to switch to a mechanical dryer.

The heat used in the thermal dryer is derived from waste heat generated by the power plant.
The electricity comes from the power produced within the mill’s power plant.
All direct carbon emissions are assumed to originate from biogenic sources. Additionally, the calculation includes other greenhouse gases, such as methane (CH4) and nitrous oxide (N2O), emitted from combustion. Indirect emissions from fuel transportation are also factored into the calculation.

In baseline situation 2, there is no fuel drying in place before feeding the fuel to the power plant.

The priming fuel is assumed to be introduced to the power plant to sustain a sufficiently high operating temperature.
The quantity of priming fuel required is estimated to be equivalent to the energy required for vaporizing the same volume of water from the fuel as what is extracted during mechanical drying with Hippo.
Natural gas is assumed as the priming fuel, and no losses from the combustion of natural gas are considered.

The results of baseline solutions

Results: Case pulp mill, baseline

Emission source	Emissions in baseline solution scenario 1 [kgCO2e/MWh]	Emissions in baseline solution scenario 2 [kgCO2e/MWh]
Electricity used in dryer	1,41	0
Electricity used in conveyer	0	0
Natural gas used in thermal dryer	0	50
Emissions from burning residue (fossil)	0	0
Emissions from burning residue (biogenic)	0	0
Total emissions (fossil)	1,41	50

And how does the Saalasti solution compare the baseline solutions? It can be seen that there are less emissions in Saalasti technology.

Hippo can save energy compared to baseline solutions.

Results: case pulp mill, handprint

Emission source	Emissions in Saalasti solution [kgCO2e/MWh]
Saalasti product manufacturing and transportation	0,06
Electricity used in dryer	0,2
Wastewater treatment	0,1
Electricity used in conveyor	0
Natural gas used in thermal drier (not valid for Saalasti)	0
Emissions from burning residue (fossil)	0
Emissions from burning residue (biogenic)	0
Total emissions (fossil)	0,4

For companies utilizing the Hippo, its usage enables a reduction in CO2e emissions compared to the prevailing practices in the industry.

Overall results of carbon handprint

Compared to other solutions, Saalasti’s technology generates significantly less carbon dioxide emissions.

Carbon handprint of in case pulp mill: 25,3 kgCO2e / produced MWh

	Emissions in Saalasti solution [kgCO2e/MWh]	Emissions in baseline solution, average of scenario 1 and 2 [kgCO2e/MWh]
Total emissions (fossil)	0,43	25,71

Example: Annual handprint of 100 MWh power plant

Annual production: 792 000 MWh
Carbon handprint per year: 20 023 tCO2e
Equals annual emissions of approximately 2000 Finns

Advocating for the green transition

At the heart of all our calculations is that we want to validate our impact based on measured data. We are committed to reducing our climate footprint in close cooperation with our stakeholders.

Saalasti’s CEO, Petteri Korpioja, encapsulates our mission:

“We are delighted to learn that Hippo’s carbon handprint is comparable to baseline solutions. Naturally, we had a hunch, but now we also have a calculated result.”

“At Saalasti, we work diligently to provide our customers with solutions that drive the green transition. The handprint calculations of Hippo affirm that we are firmly on the right path.”

The information derived from carbon footprint calculations is also valuable for Saalasti’s employees and partners.

“Furthermore, we gained valuable and measurable insights into Saalasti’s carbon footprint, which is also crucial for our operations as we aim to reduce it.”

Contact us to hear more!
CEO Petteri Korpioja
petteri.korpioja@saalasti.fi

Wood fibers in growing media: the potential to replace peat in a more sustainable way

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.

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.

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

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%.

Thermal dryer vs. Saalasti dewatering press

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 >>

Saalasti in Canada: Meeting the demands for wood processing with full service, OEM warehouse, and optimal logistics

“With the same time zone and local warehouse, we can serve our customers quickly and efficiently with optimal logistics”, explains Tero Toikka, the CEO of Saalasti Canada and USA.

Established in 2016, Saalasti’s Canada site situates in Nanaimo in British Columbia, one of North America’s major forest industry regions. The location allows to cater to the needs of customers in the North American area operating in the forestry and pulp industries.

Read ahead and discover the distinctive features that set Saalasti’s services in Canada apart.

The power of local presence: Seamless communication and prompt assistance

There was already a steady customer base before establishing Saalasti’s site in Canada, as the area is known for its high need for wood processing. When the previous agency retired, it was natural to establish the Saalasti site.

“The best way that a Finland-based company can serve its customers overseas reliably is to establish a local site with all services. Located near Vancouver, one of Canada’s largest cities, the site provides convenient access to customers in the region”, Toikka says.

Toikka also emphasizes that local presence enables smooth communication and fosters trust. Customer relationships are indeed long-lasting, spanning over the years.

“As we are in the same North American dialing code area, communication becomes seamless and immediate. This advantage is particularly important, considering that it is uncommon for individuals to have phone connections enabling international calls beyond North America.”

“With the Canada site operating in the same time zone, customers can easily reach out for prompt assistance, ensuring minimal waiting times”, he adds.

Meeting strict quality requirements for wood drying and processing

Saalasti’s machines have long been trusted in areas with strict quality requirements specifically for wood drying. The machines can handle various kinds of biomasses and wood qualities, including coastal hog fuel, which is a specialty of the West Coast.

“The coastal logs are transported across the ocean, and thus it has different drying requirements than the inland log. As the material differs from the inland log, there is also a need for high-performing presses and cutters”, Toikka explains.

Saalasti machines are trusted also in drying of unique coastal hog fuel that is transported across the ocean.

Saalasti services in Canada

Lifecycle services and maintenance for all Saalasti machines.
Machine installations and upgrades.
OEM parts and spare parts from Saalasti’s warehouse: 3,400 sqft warehouse is dedicated to North American customers.
Employs four persons.
Partnership with Prometec, a Finnish high-tech company specializing in biomass analysis.

Collaboration with Prometec enables precise and automated analysis of biomass, for example, for quality development and improvement. Learn more about Prometec’s services on their website.

The Canada site stands out in Saalasti’s global network due to the local warehouse and the partnership with Prometec.

Saalasti Canada site — Saalasti shop truck and Canadian millwrights Chris and Cory.

Seamless supply chain: local warehouse ensures timely deliveries

Saalasti’s own spare parts warehouse plays a significant role in enabling smooth customer production. With a storage capacity of 3,400 sqft, Saalasti maintains a substantial stock of original equipment manufacturer OEM products.

Saalasti Canada’s 3,400 square feet warehouse has a large selection of OEM products.

“The spare parts warehouse was established because it allows for timely deliveries directly from the same geographical area. This minimizes downtimes and unexpected disruptions in our customers’ facilities”, Toikka says.

Predicting maintenance and spare parts replacement is essential in Saalasti’s lifecycle services to ensure smooth customer production.

“We conduct monthly analyses of customer part requirements and perform annual maintenance inspections. In this way we can ensure that our customers will have the right spare parts on time and their operation can continue seamlessly”, Toikka ends.

Do you want to hear more about Saalasti services in Canada? Contact us!

Tero Toikka

CEO of Saalasti Canada and USA

+1 250 714 2433

tero.toikka@saalasti.com

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.

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.

Biomass crusher horizontal — Saalasti Crush H for biomass

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!

Learning together with customers keeps the wheels running in Saalasti Spain

“We have seen an improvement in energy efficiency and overall performance in our customer’s sites with the help of our local services,” says Jarno Petäkoski, Saalasti Spain’s General Manager, as he sums up the benefits of working closely with customers.

Located in the majestic mountain region of Léon, northern Spain, the Saalasti Spain site has been operational since 2019. We offer a complete range of services from Spain, including machine installations, maintenance, and manufacturing of new parts. The customer base includes paper and pulp mills, pellet manufacturers, and power plants.

Keep reading to learn more about why our customers trust our services in Spain and how our team approaches customer work.

The presence of the original manufacturer ensures high-performing machines

There are many benefits to our clients when they use the services, spare parts, and products of the original manufacturer. The Saalasti machines are robust and top-quality, and we ensure that working near customers.

All in all, the daily operation of the machines is easier for our clients, as we are near. As Petäkoski says:

“When we are closely present in the customer’s process, we can tailor the best solutions. For example, we can manufacture customized wear parts that fit the customer’s process just perfectly.”

“It’s important to learn about our customers’ processes, and visiting their sites helps us do that. Plus, our customers save money and avoid stress when they have access to local maintenance services within 24 hours in case of urgent needs.”

It makes a big deal when the machine manufacturer is one call away and in the same country.

Saalasti services in Spain

Serves clients in Spain, Portugal and France and, also Overseas France such as French Guiana.
Client portfolio ranges from paper and pulp, pellet manufacturers, wood chip terminals, and power plants.
Both new business services and maintenance services available.
Services: Machine installations and upgrades, maintenance and original spare parts.
Unique service: New part manufacturing in a workshop.
New facilities from 2023 onwards with a larger storage capacity.
Employs six professionals from management to service engineers and mechanics.

Saalasti Spain also operates closely with Cross Wrap, Saalasti’s subsidiary company.

Cross Wrap offers innovative solutions for bale wrapping, opening and handling with market-leading machines. The company has a long history of working with paper, plastic, cement and waste industries.

“Partnering with Cross Wrap allows us to provide even more value to our customers. Additionally, Cross Wrap has a strong presence in the Italian market, which we can now tap into as a result of this partnership”, Petäkoski says.

Customised top-notch parts from our workshop

One of the unique services offered by Saalasti Spain is the in-house manufacturing of parts for our machines.

Our on-site workshop has a range of capabilities, including a machining center, robotic welding, and manual welding.

In-house manufacturing also provides advantages in terms of predictability and cost efficiency.

”Thanks to our on-site manufacturing, we can offer custom parts tailored to our customer’s processes rather than relying on outsourced parts.”

”By controlling the entire manufacturing chain, we can offer reliable delivery to our customers. By this, we can also provide more predictable prices for the raw materials”, Petäkoski says.

In addition to manufacturing new parts, we also offer a rebuilding service for worn parts. When it is possible to renovate existing components, we can restore them to like-new condition. Saalasti machines are built to last for decades, and rebuilding is an essential part of maintaining them, in addition to timely maintenance.

Emphasising teamwork while learning together with our customers

Saalasti Spain is known not only for its high-quality machines and parts but also for its service-oriented approach. We believe in collaborating with our clients and working alongside them rather than above them.

According to Service & Project Manager Luis Miguel Rosales and Production & Safety manager Julio Barthe, Saalasti’s mindset encourages employees to solve problems creatively.

“The most important thing in my job is to think about how we can deliver the best results to our clients. So when I am not working on-site or communicating with clients, I can be working with the robot machine, designing new tools, and reporting for example”, Rosales says.

“At Saalasti, our focus is on helping our clients improve their processes. Whether it’s through spare parts, technical assistance, or managing maintenance operations, our goal is always to boost our clients’ production levels”, Barthe adds.

Both Julio and Luis Miguel emphasise the benefits of being a family-run business, which fosters teamwork and a sense of shared success.

As Luis Miguel puts it, “It’s great that we are a family company and we work as a team for the benefit of the customer. We always think about how we can work smarter and share ideas with others.”

“Once you start working at Saalasti, you’ll quickly notice that coming up with new ideas and improving processes is almost automatic and a vital part of your job,” he ends.

Do you want to hear more about our services in Spain, Portugal, or France? Contact us and let’s discuss how we can help you!

Biochar production – The benefits of high-performing biomass pre-processing

Biochar production offers significant opportunities to pursue carbon neutrality and promote the green transition, for example, in the construction and infrastructure sectors. Moreover, the new industrial market for this “black gold” is steadily growing, which also means the need for efficient biochar production will increase strongly.

The idea of biochar is not exactly new, but the market is expected rapidly. Biochar is essential when there is a need to speed up the green transition and carbon-negative goals in many industries.

Only in Europe, the biochar market grew by approximately 80 % in the year 2021, and everything seems to indicate that the trend is growing.

Read ahead and learn why biochar is essential in controlling climate change and how to make your plant’s biochar production process more efficient.

Saalasti is involved in biochar processing with efficient mechanical dewatering and particle size reduction methods.

Biochar production depends on the biomass

Biochar is produced in pyrolysis, where organic material is heated to a high temperature in a low-oxygen environment. This creates a stable carbon-rich material with a larger surface area and a porous structure. As a result, there will be carbon that does not release into the atmosphere.

Biochar is mainly produced from plant-based biomasses, such as by-products from the wood industry, straws, or demolition wood. However, a growing tree still binds carbon in its trunk, so using side streams for biochar is more beneficial than growing trees.

We offer solutions for fiber-based biomasses used in biochar production.

The quality of biomass is a crucial factor in the final quality and potential uses of biochar. There is no one-size-fits-all biochar, as different types of biochar are suitable for different purposes.

The properties of biochar are affected by the raw material, the production process, and post-treatment—also, the particle size of the biochar matters. A larger size of biochar is considered better for improving soil ventilation, while a finer size of biochar is more suitable for supporting beneficial microbes.

When scaling up biochar production, it is crucial to ensure that the biomass used in the process is high quality, suitable for the intended purpose, and produced efficiently.

A perfect solution in projects committed to carbon neutral or carbon negative goals

There is a good reason why biochar is expected to be the next big thing to curb carbon emissions.

Mention some benefits of biomass:

Biochar is a carbon sink that absorbs more carbon from the atmosphere than it releases. One ton of biochar absorbs 3.7 tons of carbon dioxide. For example, the emissions of an average passenger car are around 2100 kg CO₂/year. One ton of biochar offsets the annual emissions of about two passenger cars.
Biochar improves the soil’s nutrient binding and water retention capacity and adds to the soil’s porosity.
Can bind/absorb hazardous chemicals and compounds, such as heavy metals and pesticides.
It has a great water retention capacity and can bind five times the amount.

One ton of biochar can absorb 3.7 tons of carbon dioxide.

There are several uses for biochar in the infrastructure and building sector, and new applications are constantly being developed.

Applications of biochar:

In the construction sector, biochar can be used, for example, in green areas to improve the soil.
Biochar can be used to treat water and urban runoffs.
To purify the soil and water systems.
Biochar can also replace fossil coal and coke in the steel industry. For example, in Finland, there are plans to manufacture coke from forestry waste in the Outokumpu steel plant. The solutions are expected to reduce carbon emissions significantly.

At Saalasti, we can partner up with all the cases mentioned above of biochar, and we are eager to step into new biochar applications.

How to get the most out of biochar production with high-performing pre-processing?

Every stage of biochar production is crucial to the quality of the result. Pre-processing plays a significant role in ensuring the biomass is sufficiently dry and stable-sized before pyrolysis.

We offer solutions for processing biomass before the pyrolysis process:

1. Reduction and standardization of the particle size.

Crushing biomass is a crucial step in the early stage of biochar production. When the particle size is controlled, it results in a more uniform mass that can be utilized with greater efficiency. Saalasti Biomass Crushers are the market-leading solutions for particle size reduction.

Read more: Reduction of particle size

2. Mechanical dewatering of the biomass.

The dryer the biomass is before pyrolysis, the more you can expect energy savings while reducing operating costs and carbon footprint. With our mechanical drying solutions, we can reduce the water content drastically of any fiber-based biomass.

With our solution, it is possible to save up to 50% of energy usage in biochar production compared to thermal drying.

The best machines for mechanical dewatering include the Saalasti High-Pressure dewatering press “Hippo” and the market-leading Bark Press.

Read more: Mechanical dewatering

The benefits of Saalasti solutions in biochar production:

1) Up to 50 % energy savings in the drying process.

2) More homogenous and better-quality material improves productivity and allows capacity scaling.

3) No more seasonal fluctuation in production, as the biomass has a steady, even quality year-round.

The mechanical drying technology used by Saalasti is unique globally. We are the only operator offering this particular mechanical drying technology.

Do you want to hear how our solutions can support your biochar production? Contact us!

Read customer story: Maximal production volume with the same amount of heat (Van Roje)

Biomass power plant solutions: How to turn biomass into value | Customer stories

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).

A recap of Saalasti year 2022: 15% growth in a rapidly changing business environment

How was the year 2022 for Saalasti Finland? Although many unexpected things happened worldwide, we increased our turnover by 15% according to our target. The energy crisis accelerated the green transition and has opened up many new opportunities for us. Bioenergy is a compelling solution in the current market situation, especially because of its adjustability and storability.

In this blog post, we look over the year 2022 with Petteri Korpioja, the CEO of Saalasti Finland.

– In 2022, we reached an all-time high in the annual turnover of Saalasti Finland. Also, at the group level, we made a record in turnover. Considering the challenging world situation, this is an excellent performance. The year’s events have shown that we can avoid risks more effectively by working only with democratic countries, states Korpioja.

Saalasti Petteri Korpioja — Petteri Korpioja, CEO of Saalasti.

New records in several business areas and the first outside EU deliveries of HIPPO

Despite the challenging times, we increased our turnover by 15% and hit a new record for Saalasti Finland. The key factors were the positive results in sales to new customers and our lifecycle services. The turnover of new sales to customers was in total 8 million.

The year 2022 was successful for the whole Saalasti Group. At the end of 2022, our subsidiary, baling and wrapping operator Cross Wrap set a record for new orders by over 40% increase. It allows us to expect strong growth also in 2023.

Our other subsidiary, railway specialist Teräspyörä-Steelwheel also succeeded in its business goals in the past year. In 2023 we expect Teräspyörä to continue the good development path and strong profit-making ability.

One of the highlights of Saalasti last year was starting the first major deliveries of Hippo, an innovative high-pressure press SP 1803. Hippo offers high drying efficiency and huge energy-saving potential. The feedback in the field has been very positive, and this year we see strong growth potential in the customer base of Hippo.

The previously published Saalasti Press has been the market leader for decades, and with Hippo, we are looking for new market openings, says Korpioja.

Turbulence in the raw material market – the Saalasti team adapted to changes quickly

In the spring of 2022, we faced new challenges in our business. The material shortage resulting from the war in Europe and especially the doubling of the price of steel caused significant changes and challenges in the market.

– Due to Russia’s war in Ukraine, raw material prices skyrocketed, and material availability decreased. We at Saalasti reacted with strong inventory and by developing our subcontractor network, Korpioja says.

Our production team faced these challenges at the front line. Completing orders in 2022 required a lot of rescheduling and reorganization of the work queues. All orders were delivered as agreed – thanks to the solution-orientedness and flexibility of our team.

Within 2022, we reorganized many of our processes and operations to better respond to larger delivery volumes and projects in the future. The strengthening of these abilities will also continue in 2023.

Towards strategic subcontracting partnerships globally

The past year, our focus has been on creating resilience and finding alternative ways of working if the primary plan has to be changed. We have to tie new international partnerships to guarantee the continuity of our operations in surprising situations and better monitor our delivery times.

In 2022, many projects were delayed due to factors influencing the entire industry. Spikes in sick leaves caused by the coronavirus, raw material shortage and production load required a review of our operating models.

– Recently our focus has been on how to act against supply and availability disruptions in the long term. We have developed, for example, our storage of certain components. We always have high-quality original spare parts available for our customers, tells Korpioja.

We have done significant work in procurement to increase our international procurement network and improve our supplier control. That will enhance the competitiveness of the Saalasti Group in the long term.

The war in Europe demands drawing clear lines: Saalasti stands for democracy in all of its operations

One lesson from 2022 is to work with subcontractors that follow democracy. That will reduce risks and underline the values we at Saalasti group want to support.

– Russia’s war in Ukraine put us in a difficult position because Russia has been an important market area for all of the companies in the Saalasti group. In the end, there was only one possible solution: we completely withdrew from the Russian market like many other Finnish and international companies. We at Saalasti group no longer do business with totalitarian or authoritarian states. The risks are too high, but it’s also a value choice for us. We are on the side of democracy, Korpioja emphasizes.

Despite the outbreak of the war, we have continued to work on the agreed projects in Ukraine.

– It has been important to us that we strive to complete all started projects in Ukraine, even though it is challenging under the current circumstances. We have also supported Ukraine in other ways, for example by making a large donation to Ukrainian children, Korpioja continues.

Russia used to be a big market area for our maintenance services, so it’s notable that we were able to make an all-time high also in the maintenance business unit turnover.

The global bioenergy market is growing even more year 2023 – investments in innovative development will continue

In 2023, Saalasti Finland aims for a 21–22 million turnover. The total turnover target for Saalasti Group is 40 million.

We will continue with the organizational changes and investments started in 2022 to better meet our customer’s needs in the coming years. We are the market leader in biomass processing solutions and part of the green transition.

The energy revolution is proceeding and affecting all industrial operators.

As a consequence of the energy crisis, interest in bioenergy has grown. That’s primarily due to its adjustability and storability. The renewal of the energy industry will open up many opportunities for us. For example, the pellet market is growing strongly in Europe, and we are a steady partner in the sustainable pellet industry.

The war in Europe has speeded up the green transition, showing that the world can quickly make significant changes in the energy markets. In the long term, our development plans are on the development of non-burning forms of energy.

Do you want to hear more about Saalasti solutions and the partnership we could start in 2023? Contact us, and let’s discuss the needs of your production.

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

In the wood pellet production, German company Van Roje was able to raise 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 need to raise capacity and modernise pellet production

Energiepellets Oberhonnefeld, part of van Roje, has specialised in sustainable pellet production since 2007. The company has one of the leading softwood sawmills in Europe with a long company history.

The sawmill produces wood chips and sawdust, which are processed into FSC and EN plus certified wood pellets on the Oberhonnefeld site. The high-quality wood pellets are made only from natural sawdust without artificial binders. The energy for the pellet production comes from the company’s heating plant, which offers renewable energy for production.

Van Roje planned to grow its pellet production from approximately 40 000 tonnes to 80–90 000 tonnes per year. But there was a question about heating and drying capacity and how it could answer to increasing demands of capacity raise. The belt dryer was fully in operation, while the heating plant was close to the upper limit of its capacity.

− The problem was that we did not have enough heat in our heating plant to raise the pellet production volume. And then we heard about the new Saalasti press, says Gerhard Hauschulte, the Managing Director of van Roje.

Van Roje pellet production machine — Gerhard Hauschulte, the Managing Director of van Roje

Higher production rate and massive energy savings year-round

The solution to boosting productivity came with the new Saalasti Press 1803, also known as ”Hippo”. The new press is a mechanical dewatering solution, which reduces the moisture content of biomasses such as wood chips and sawdust. The ”Hippo” press is the newest version of Saalasti presses, which have been market leaders many years before.

The benefits of the new technology soon became apparent. The press drastically reduces raw wood’s moisture content while connected upstream of the belt dryer. The water content of the wood that van Roje uses is about 40 % before the drying process.

The press reduces about 55 % moisture from the material, which is a very big improvement.

Thanks to the lower water content of the biomass, the belt dryer’s performance is maximised with the same thermal energy. This meant that van Roje had also gained massive energy savings.

– There was no need to invest in energy production or an additional combustion system. Otherwise, we would have needed a bigger belt dryer, Hauschulte adds.

The moisture removal is so effective that the operation stays steady year-round, which was not the case before.

– Normally, our capacity would be smaller in the winter, but now we can run our operation steadily year-round. Without the presses, we would have about 50 % less capacity in our pellet production, Hauschulte highlights.

Top-quality material with lower pellet production cost

The innovative solution was convincing, as it was tailored to the needs of van Roje, as Hauschulte says.

− It was very important that the solution could be able to press both sawdust and wood chips. Saalasti was the only one who could provide a viable technical solution for the use of sawdust also.

The press also improves the quality of the dry material. The wood chips are pre-crushed in the press, which increases the evaporation surface of the material. The material will thus be more homogenous overall, while the whole thermal drying process will be more efficient.

Press is a long-term investment that will pay itself back in several ways. The machine enables greater capacity while saving energy, and there are continuous savings on the pellet production costs.

The production cost per tonne is much cheaper with the press, while the energy savings are huge.

− I have recommended this solution to several companies with the same operation as us. The heavy construction of the machine is also a good thing, and its operation is very reliable, Hauschulte ends.

The benefits in short

Higher production volume with the same amount of heat; no need to add energy consumption.
Removes the moisture content from both wood chips and sawdust dramatically.
The quality of the dry material is improved in the crushing and drying process.
Year-round steady operation is possible.

Contact us to hear more about our solutions for pellet production

Do you want to hear more about Saalasti solutions? Contact us, and let’s discuss the needs of your production.

>> Contact us

Partnering Chilean biomass industry with first-class service – Get to know the Saalasti Chile branch

Thanks to our top-quality machines, service, and the mutual trust with our clients and partners, we have rooted success in Chile. – Nicolas Rönning, the General Manager of Saalasti Chile.

Saalasti has years of business history in Chile where we offer a complete local service from new machine installations to maintenance and machine rebuilds. Our Chilean headquarters are located in Hualpén in the metropolitan area of Concepción, in Central Chile.

Read ahead and get to know our base for South American business!

A reliable partner to the pulp and paper industry in Chile

Strong pulp and paper industries are common in both Saalasti’s countries of origin – Finland and Chile. As a market leader in biomass machines, we offer local services to our clients in our biggest market areas. Saalasti’s clients in Chile mostly consist of pulp mills whose operators we help with sustainable solutions.

Setting up a branch office in Chile was needed because machine and spare part deliveries had been done to Chile for years.

– There were already many Saalasti machines in Chile so it was a natural step to grow our presence locally in Chile, Rönning says.

Rönning has been working with Saalasti for many years. Before the Saalasti Chile office started in full pace in 2017 he was working for a company representing Saalasti in Chile.

There are more than 25 Saalasti machines in Chile – including Saalasti Crushers, Chippers, and Presses.

Even though Saalasti Chile is geographically far from headquarters and other Saalasti offices in Sweden, Canada, and Spain, communication between the offices is close-knit.

We have excellent relations with the other Saalasti offices. We learn a lot from one another by sharing ideas and thoughts that help our clients. When we support one another, we ensure the best possible service to our clients, Rönning states.

What services does Saalasti offer in Chile?

From our Chilean site, we offer a vast range of our services:

Installations and hands-on training of the Saalasti machines
Site services
Maintenance and lifecycle services
Spare parts for the Saalasti machines
Machine rebuilding and recuperation

The growth that Saalasti Chile has had during the years is not only related to Saalasti machines, but during the years, in Chile we have developed different business areas that are related to the wood industry. They are like;

Representation of Nicholson debarkers, worldwide log debarkers for sawmill industry.
Cutting tools sales agents for saw and pulp mills.
Technology area that provides its own developments solutions to saw and pulp mills.

Besides, with our reliable and curated partners, we offer a stronger overall service to our customers.

Speaking of Saalasti workers, Saalasti Chile provides employment to approximately 30 persons, including sales, administration, maintenance, and services in our workshop.

We are also happy to say that we are a Great Place to Work certified organization that cares about its employers. Our Chilean branch also gained very high points in the GPTW survey, which measures employer experience and satisfaction.

Saalasti office

Rebuilding improves the machine lifecycle

In Chile, the rebuilding of machine parts is a big part of Saalasti’s services. We have established a workshop where our professionals are specialized in repairing worn parts of Saalasti machines. The rebuilding is usually done in our workshop, but it can also be done on our customer’s site.

– Saalasti’s rebuilding workshop makes machine parts new again. Our robust machines are meant to last decades, and one important thing is to ensure the good condition of hard-wearing parts, Rönning says.

In rebuilding or recuperation, we rebuild parts to the original dimensions and tolerances. In our workshops, we sample recuperate the parts with quality welding.

Rebuilding makes machine parts new again.

The rebuilding scope is tailored to the customer’s needs. For example, for Saalasti Chippers and Crushers, we can rebuild the rotors, crusher bars, and grates while we replace worn parts.

Saalasti Chile also provides fast rebuilding and maintenance services locally.

– And when the rebuild is not the best option anymore, naturally, we offer original spare parts for all Saalasti machines, Rönning adds.

Saalasti rebuilding

Trust and top-quality service behind every happy client

When talking about customer satisfaction, gaining and maintaining trust have been the key elements in Chile, just like in other countries.

“Promises made are promises kept” mindset is shared by all Saalasti branches internationally.

The key element for building long-lasting trust is understanding what our customers value.

– Our clients are satisfied because Saalasti can find the right solution for their machines. By using the right materials, and offering quality maintenance by our professionals, we ensure the best lifecycle for the Saalasti machines, Rönning highlights.

And it goes without saying that all of our services always strive to enhance our client’s business.

– We always care about the customer’s money. We have satisfied clients, as we have been able to increase the operativity of our machines, he adds.

We always care about the customer’s money. Our clients are satisfied because Saalasti can find the right solution for their machines.

Also, we take full responsibility for our actions in every situation.

– Being honest is a very important value for us. If we make a mistake – which nobody wants – we take responsibility for that and fix things, he states.

In a digital world, face-to-face meetings are still important

Saalasti has strengthened its position in the Chile office over the past few years, during which the world has changed a lot. What does the future look like for Saalasti in Chile?

Now that worldwide travel restrictions have been eased, there will be more socialising and traveling to client meetings. Although digitalisation is rapidly going forward, it can’t completely replace face-to-face meetings.

– It looks like 2023 is finally going to be the year for traveling and socialising. More trade shows, client meetings, and new grand openings. I travel a lot for my job and regularly meet our customers, partners, and contacts on their sites and during fairs. It’s very important to be on the field to provide the best service to our partners, Rönning says.

In the future, Saalasti will strengthen its position further in other parts of South America. For example in Brazil where there is a demand for sustainable paper and pulp solutions.

Last but not least, Saalasti is an apparent operator locally. We actively partake in supporting the local community.

– We also do good for the community. To mention one thing, we sponsor the local rugby club and soccer teams that bring joy to people’s spare time, Rönning states.

Do you want to hear more about Saalasti services in Chile?

Contact us and we will happily tell more about how our sustainable solutions can help your biomass business.

Nicolas Rönning +56 9 6596 0605, nicolas.ronning(a)saalasti.com

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

Did you know that our oldest machines have been operating continuously since the 1980s?

To sum up why our machines are top-performing decade after decade, it would all come down to maintenance and lifecycle services. With our professional service, we ensure that our clients can make the most of their investments.

Sustainability is our core value, which reflects on our machines concretely. They are sustainable in many ways; they help our customers to operate effectively with sustainable biomass, but they also sustain their value for decades.

Read further and learn about the benefits of our lifecycle and maintenance services and why you should choose us as a service partner.

You will get to know about the benefits of our maintenance services directly from our hands-on performers. Tips will be shared by Janne Kuuseva, Service Manager Finland and Antti Kumpumäki, Service Manager Team Leader in Finland.

Protect the performance line but also the people

As we know, for any company, top-performing machines are crucial for their production and bottom line. At the same time, it’s noted that machine maintenance does protect not only your bottom line, but also every employee who operates the machine.

Our vast services ensure that your Saalasti machine is both top-performing and productive but also safe to operate. It also goes without saying that our machines are compatible with high-reliability performance.

Our maintenance services include everything that will keep your machine healthy:

Maintenance for all Saalasti machines according to your needs: from changing consumable parts to turnkey contracts.
Lifecycle services including, for example, preventive maintenance and service inspections.
Original equipment manufacturing (OEM) spare parts for all Saalasti machines worldwide.
Machinery updates where we optimise your machines to your current needs. This is a far more cost-efficient solution than investing in a completely new machine.
The machine’s maintenance history and reports are always available to you.

Read more about our services.

Service inspection reveals upcoming maintenance targets

Preventive measures are at the core of our lifecycle services. With them, you can enjoy the high performance of the machine and prevent unexpected maintenance needs.

To make sure that our clients have the best operation, we offer service inspections.

In service inspections, we review the condition of your machine and any future measures that require maintenance, such as the need for consumable parts and machine upgrades.

“Service inspections are a good arrangement for both our clients and us. While our client can prepare themselves for upcoming reparations, we can schedule our maintenance beforehand and reserve the right resources for every asset”, Kuuseva says.

Usually, service inspections are made twice a year on-site at your factory. During the two-day inspection, we check the condition of the machine when it’s running and when it’s not in use.

Thanks to service inspection, you can also supply critical components well in advance.

“It is definitely a good thing for the customer that we can assess the need to replace certain components and parts in advance. This way we can order the components beforehand and install them at the right time”, Kumpumäki says.

The core of service inspection is always to ensure the seamless performance of your machine.

“No one wants unexpected maintenance costs and untimely downtimes. With service inspection, we support our clients to know the upcoming maintenance needs ahead of time”, Kuuseva adds.

Minimising downtimes with timely service

Saalasti’s robust machines are essential to your processes and production lines. So we are often asked, how long will the maintenance take and how will it affect production lines?

In many cases, our maintenance will not affect your production performance at all.

“If there are two or more Saalasti machines in one plant, we can arrange maintenance with no downtime at all”, Kumpumäki says.

“And to plants with only one Saalasti machine, service inspection and proactive maintenance are really important. With them, we can schedule the maintenance for a time slot that’s the most convenient for the client”, he adds.

Scheduling maintenance according to seasons is often a good idea, especially in the northern areas.

“If you’re wondering whether it’s better to have your machine’s maintenance done before or after the winter, it’s always better to schedule it before winter. The machine will be fully functional for the challenging season well in advance. Also, maintenance is not needed when energy is being consumed the most”, Kumpumäki points out.

Dedicated professionals at your service

When thinking about why you can rely on Saalasti’s services, there are many reasons.

“It’s safe to say that as a manufacturing company, we have the best expertise, special skills and tools to take care of Saalasti machines”, Kuuseva says.

“Each maintenance staff member is given a thorough hands-on training with our machines. No degree teaches you how to use and maintain Saalasti machines, so everyone gets an up-to-date and practical introduction to them, ” he adds.

It is also worth noting that we always aim to work as near the client as possible with our local services.

As a global market leader of biomass machines, we will serve our clients all over the world in different languages.

Our clients are happy with our fast reaction times with the right actions and flexible services. For example, because of the wide range of available components, we can replace consumable parts if we notice there is a need for that.

And in case there are any unexpected issues, you will reach us quickly.

“We always respond within 24 hours, and if the situation is critical, we will quickly be at your factory”, Kuuseva notes.

We offer different maintenance services from changing single components to anticipatory maintenance to annual maintenance.

Checklist to Saalasti machine maintenance

Preventive maintenance ensures the reliable performance of the robust machine.
Service inspections will pay for themselves, as you can prepare for future maintenance needs well in advance.
Need a tailored maintenance solution? We can arrange that according to your needs!
Machine updates can save you from new investments.
Is the situation critical? Call your local maintenance and we will take care of it.

Do you want to hear more about our maintenance services?

All Saalasti machines are meant to last decades, not years. We will ensure the performance with our vast after-sales services all over the world.

Contact your local Maintenance Manager here.

Horizontal chipper helps to raise the capacity of biopower plant

More efficiency and lower usage of fossil fuels compared to a mobile crusher

Smooth communication throughout the delivery process

Horizontal chipper delivered to biopower plant will ease the shift away from fossil fuels

Improve the performance of your machine with an upgrade

We had our climate impacts calculated: Saalasti’s carbon footprint and Hippo’s handprint

Wood fibers in growing media: the potential to replace peat in a more sustainable way

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

Machine upgrades will increase performance and productivity

Case: Upgrading bark presses to improve performance for years ahead

What types of machine upgrades does Saalasti offer?

Why should continuous maintenance not be forgotten?

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

Horizontal chipper delivered to biopower plant will ease the shift away from fossil fuels

Improve the performance of your machine with an upgrade

We had our climate impacts calculated: Saalasti’s carbon footprint and Hippo’s handprint

Wood fibers in growing media: the potential to replace peat in a more sustainable way

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

How was the carbon footprint calculated?

Saalasti Finland Oy carbon footprint 2022:

The results for Hippo

Carbon footprint of Hippo, total

And what about carbon handprint?

Handprint calculated: How does Hippo compare with other solutions in biomass drying?

The results of baseline solutions

Overall results of carbon handprint

Advocating for the green transition

Horizontal chipper delivered to biopower plant will ease the shift away from fossil fuels

Improve the performance of your machine with an upgrade

We had our climate impacts calculated: Saalasti’s carbon footprint and Hippo’s handprint

Wood fibers in growing media: the potential to replace peat in a more sustainable way

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

Wood fiber can be a sustainable substitute for peat

Benefits of wood fiber in growing media:

The quality of the wood fiber matters

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

Saalasti solutions that can be applied to wood fiber processing

Contact us to hear more

Horizontal chipper delivered to biopower plant will ease the shift away from fossil fuels

Improve the performance of your machine with an upgrade

We had our climate impacts calculated: Saalasti’s carbon footprint and Hippo’s handprint

Wood fibers in growing media: the potential to replace peat in a more sustainable way

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

The dewatering press is the industry standard for biomass drying

Mechanical drying vs thermal drying?

When comparing cubic meters of water removal,

Mechanical drying advantages

The new-generation dewatering press reduces moisture content drastically

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

Want to know more about market-leading dewatering presses?

Horizontal chipper delivered to biopower plant will ease the shift away from fossil fuels

Improve the performance of your machine with an upgrade

We had our climate impacts calculated: Saalasti’s carbon footprint and Hippo’s handprint

Wood fibers in growing media: the potential to replace peat in a more sustainable way

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

The power of local presence: Seamless communication and prompt assistance

Meeting strict quality requirements for wood drying and processing

Saalasti services in Canada

Seamless supply chain: local warehouse ensures timely deliveries

Horizontal chipper delivered to biopower plant will ease the shift away from fossil fuels

Improve the performance of your machine with an upgrade

We had our climate impacts calculated: Saalasti’s carbon footprint and Hippo’s handprint

Wood fibers in growing media: the potential to replace peat in a more sustainable way

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

Biomass processing means a shift away from fossil fuels

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?

2. Does the capacity flex according to your needs?

3. What is the expected lifecycle of the machine?

4. How does the process consider energy efficiency?

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

Get to know market-leading biomass processing machines

Contact us to get the most out of biomass processing

Horizontal chipper delivered to biopower plant will ease the shift away from fossil fuels

Improve the performance of your machine with an upgrade

We had our climate impacts calculated: Saalasti’s carbon footprint and Hippo’s handprint

Wood fibers in growing media: the potential to replace peat in a more sustainable way