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Wood biomass is turned into industrial fuel through chipping. The efficiency of chipping depends on many factors, including chipper knife wear. Chipper knife wear was determined through a long-term follow-up study, conducted at a waste wood recycling yard. Knife wear determined a sharp drop of productivity (>20%) and a severe decay in product quality. Dry sharpening with a grinder mitigated this effect, but it could not replace proper wet sharpening. Increasing the frequency of wet sharpening sessions determined a moderate increase of knife depreciation cost, but it could drastically enhance machine performance and reduce biomass processing cost. Since benefits largely exceed costs, increasing the frequency of wet sharpening sessions may be an effective measure for reducing overall chipping cost. If the main goal of a chipper operator is to increase productivity and/or decrease fuel consumption, then managing knife wear should be a primary target. (C) 2014 Elsevier Ltd. All rights reserved.

A commercial drum chipper was fed alternately and piecewise with poplar stems and poplar tops, in order to determine the effect of piece size and tree part on machine performance. Chipping stems required most of the available power (231 kW) delivered by the tractor, whereas chipping tops took about half that much. However, productivity was twice as high with stems, compared to tops (i.e. 25 and 11 t h-1 of oven dry wood, respectively). As a consequence, specific fuel consumption per unit product was 15% lower with stems, compared to tops - i.e. 0.61 and 0.72 L m-3, respectively. Mean feeding speed was 0.37 m s-1 for stems and 0.41 m s-1 for tops, but the difference was not significant (p = 0.1677). Productivity and fuel consumption were strongly related to piece size, but tree part had its own additional effect, independent from size and possibly related to form. When chipping tops it is advisable to feed more pieces at a time, in order to partly compensate for the effect of piece size. Operators expecting to chip primarily small-size materials may acquire special chipper versions with wider drums and additional side rollers, for smoother mass feeding. oThe same chipper was tested with poplar stems and tops.oChipping stems resulted in higher productivity and lower fuel consumption.oChipping stems required most of the available tractor power.oChip particle size distribution was about the same for both feedstocks. © 2013 Elsevier Ltd.

In Italy, olive tree groves may offer up to a million tonnes of dry biomass per year as pruning residue. Searching for a cost-effective way to tap this potential, the authors tested a new machine, capable of recovering pruning residue at the same time as pruning. The pre-commercial prototype was tested on four different plots and compared to a simpler tractorbase mechanical pruning unit. The authors conducted detailed time-studies in order to determine machine productivity and residue recovery cost. The integrated machine can treat between 0.2 and 0.6 ha h(-1), producing between 0.33 and 1.03 tonnes of fresh residue hour(-1). Its integrated residue recovery function does not slow the pruning, which actually proceeds faster than with the tractor-base unit, due to the more efficient multiple-disc cutting bar. The marginal cost of residue recovery hovers around 40-45 (sic) fresh tonne(-1). However, the new machine must not be considered just as a biomass harvester, but rather as a mechanical pruning unit with an integrated biomass recovery function. Its main benefit derives from the capacity of performing a very effective mechanical pruning, and the residue recovery function is a secondary benefit yet unavailable on standard pruning machines. Its deployment must be seen in the context of a general effort to modernize olive grove management and to develop an integrated biomass production system, rather than as a further attempt to build a specialised biomass supply chain.

The Authors tested a complete new system for recovering wood fuel from the termination of depleted orchards. This operation can generate between 25 and 80 fresh t ha?¹, that can be directed to the growing bioenergy sector. The new system is based on highly-mobile low-investment general-purpose equipment, which allows containing operational cost and speeding relocation between work sites. The new residue collection system is quite flexible, and achieves cost-effective recovery on relatively small fields, often smaller than 1 ha. Under the conditions of the study, trees are cut, chipped and delivered at a cost between 35 and 40 EUR t?¹ (40% water mass fraction), provided that fields are within a 20 km distance from the biomass plant. Use of a standard drum chipper results in a better product quality than if a grinders is used, as is the case for conventional orchard removal operations. Feeding the chipper with a separate loader allows a significant cost reduction, provided that the field offers at least 25 t of fresh wood. In the future, use of remote controls and electronic tethers may allow a further cost reduction, which is estimated at 15%.

Industrial poplar plantations represent a strategic source of wood products for many countries. Harvested after 10 to 30 years, they yield about 200 t ha-1 of timber and 100 t ha-1 industrial wood. The latter is obtained from poplar tops, which can be converted into chips, or a mix of pulpwood and chips. The study compared four options to process poplar tops. Alternatives derived from the intersection of two product strategies (pulpwood and chips, or chips only) with two pulpwood processing methods (manual or mechanized). Both mechanization and simplification (only one product) succeeded in reducing production cost, but the former had a stronger effect. The tests demonstrated that all options were cost-effective and could return some profits. However, the exclusive production of chips offered lower profits, compared to an articulate product strategy aimed at maximising value recovery. In the case of Italian poplar plantations, the price difference between pulp and chips is generally larger than the cost reduction obtained with integral chipping. Similar conclusions were reached by other authors working with spruce and beech in Central Europe. Of course, this is only true for the current price levels of pulpwood and chips: results may change, if this price balance will be altered by the growing demand for biomass fuel.

The authors tested a 409kW forager turned into an industrial chipper through a special conversion kit. Conversion was temporary, and the forager could be returned to its original occupation with one day of work. The converted forager proved as effective as a dedicated chipper of the same power. Net chipping productivity varied between 25 and 33greenth-1. Productivity was highest with poplar tops and lowest with pine tops. Fuel consumption ranged from 1.6 to 1.8lgreent-1. Fuel consumption did not change with tree species, but increased significantly with knife wear. Temporary conversion allowed a better depreciation of the invested capital and resulted in a 25% reduction of unit chipping cost. The converted forager proved an ideal solution wherever the production of wood chips was a complementary business within the scope of a larger agricultural economy. In technical terms, this machine offered the combined advantages of road-capability and good off-road mobility, allowing low-cost independent relocation and effective in-field chipping. © 2013 Elsevier Ltd.

The growing interest in forest biomass has made chipping increasingly popular all across Europe. Many operators have equipped for the purpose, but the large variety of working conditions found in the European forests makes it difficult to correctly estimate the productivity of each specific operation, leading to uncertainty in crucial decisions, such as: operation scheduling, price setting, machinery selection and acquisition. In 2001, the Italian National Council for Research (CNR) and the University of California (UC) developed a spreadsheet freeware capable of returning reliable estimates of chipping productivity and cost, on the basis of user-defined input data. The model is still available from the CNR website and is the object of frequent downloading and inquiries. Such model contains a set of predictive equations derived from the results of 102 field trials, conducted with 30 different machines, under a range of working conditions. In order to facilitate comparison with other estimates and to achieve methodological transparency, the equations are assembled into a simple Microsoft Excel workbook, and the costs are calculated with standard costing methods currently used in Forest and Agricultural Engineering. Since then CNR has continued to work on the subject, with the goal of updating and refining the model. Such work has included 45 validation tests and a separate study on the delay (idle) time typical for different chipping operation layouts. The study was concluded in 2009 and confirms that the model developed by CNR can provide reliable estimates of chipper productivity under a range of operational conditions. Authors believe that such a model can assist European foresters in keeping ahead with the growing biomass sector, thus helping them to seize an important business opportunity.

The Authors surveyed 6 industrial chipping operations for a whole work year, collecting data about machine usage, product output, fuel consumption and chipper knife wear. Despite the challenging work conditions offered by mountain operations, industrial chipping contractors manage to achieve a high machine use, ranging from 500 to over 2,500 h year(-1). Product output varies between 18,000 and over 120,000 m(3) loose chips per year. In order to acquire enough jobs, operators may travel between 1,500 to over 20,000 km in a year. Industrial chipping contractors adopt different operational strategies to achieve their production targets, and they equip accordingly. Some operators prefer to tap smaller local areas and opt for smaller tractor-powered chippers, which are less powerful and productive than larger independent-engine units, but cheaper and capable of negotiating low-standard forest roads. Others prefer to explore larger areas and achieve higher product outputs, and they opt for larger independent-engine chippers, often mounted on trucks. Long term productivity varies with machine type: tractor-powered units produce between 40 and 50 m3 loose chips per hour, whereas larger independent-engine chippers produce between 60 and 90 m3 loose chips per hour. Specific fuel consumption is about 0.5 L diesel per m3 loose chips, regardless of chipper type. A sharp knife set can process between 200 and 1,500 m3 loose chips before getting dull. Disposable knives last longer and are cheaper to manage than standard re-usable knives. (C) 2014 Elsevier Ltd. All rights reserved.