The Mersey and Red Rose Timber Stations Project September 2003-March 2004

Report to The Countryside Agency and Commission North West England Conservancy

March 30th 2004

Gareth Mayhead Nigel Blandford Timber Project Officer Operations Manager E-mail: [email protected] E-mail: [email protected]

The Mersey Red Rose Forest Risley Moss Community Forest Centre Ordnance Avenue Dock Office Birchwood Trafford Road Warrington Salford Quays WA3 6QX Manchester M50 3XB

Tel: 01925 816 217 Tel: 0161 872 1660 Fax: 01925 821 793 Fax: 0161 872 1680 Web: www.merseyforest.org.uk Web: www.redroseforest.co.uk Contents

Contents ...... 2 Tables...... 2 Figures ...... 2 Summary...... 4 Introduction...... 5 The Need for Processing Infrastructure...... 5 Existing Timber and Processing Initiatives...... 6 Frankland Services, Altrincham...... 6 Mersey Valley Warden Service, Chorlton...... 6 Other Sub-Regional Examples...... 7 Brighton & Hove Recycling Project ...... 7 Existing Markets for Recycled and Virgin Timber...... 8 Sorting and Classification of Wood Arisings...... 8 Potential Markets...... 8 Barriers to Utilisation ...... 9 Timber Station Concepts ...... 11 Product Development ...... 11 Product Categories...... 11 Timber Choice...... 12 Sales...... 13 Process ...... 14 Product Details...... 17 Quality Issues...... 30 Funding Opportunities...... 31 Site and Planning Issues ...... 31 Potential Delivery Mechanisms ...... 31 Dissemination...... 32 Conclusions and Recommendations...... 32 Appendix...... 33

Tables

Table 1: Categories of wood (DTI, 2001)...... 8 Table 2: Wood sub-categories (AEAT, 2003) ...... 8 Table 3: Summary of products produced from locally sourced timber...... 12 Table 4: Typical donations received for wood products at events attended...... 14 Table 5: Dissemination to date...... 32

Figures

Figure 1: Sycamore logs awaiting conversion in St Helens ...... 13 Figure 2: Sycamore cants awaiting further processing...... 13 Figure 3: Initial conversion of logs ...... 15 Figure 4: Secondary processing of timber ...... 16 Figure 5: Quality issues in Beech cutting board ...... 30

Report to March 2004 2 Written by:

Checked by:

Report to March 2004 3 Summary

This report covers the Timber Stations research project that was active from September 2003 to March 2004. The main aim of the project was to establish what products could be made with locally sourced timber and to assess if these are economically viable. Work also examined site and planning issues and current examples of processing infrastructure.

The timber assessed was generally waste virgin timber that came from arboricultural operations or from woodland management work. The timber used was not of a commercial quality due to quality and form issues. Most of the material actually started with a negative value as disposal would incur costs.

The number of products produced was 17 in three broad categories graded according to the complexities of production. The project team were surprised at the number and variety of products made. The quality of the products was impressive when taking into account the nature of some of the timber that they were made from. However, care is needed with quality control to ensure production efficiency. The general public have received the products were and it appears that it is possible to command a premium for well made products produced from local timber sources. Providing interpretational resources and explaining facts about the timber used also helped to engage the public. It is concluded that sales of products are in many cases viable and sometimes potentially profitable. The optimum sales method is direct to consumers. This will maximise value and ensure a linkage with the woodland resource or .

Local authorities and tree contractors that have seen the work have been very interested and a number are keen to carry out similar projects in the future.

A comprehensive investigation into environmental and planning issues alongside analysis of suitable potential sites for Timber Stations has shown that the concept is feasible and that there suitable sites available within appropriate distances from the timber resource.

The project has successfully demonstrated that it is possible to make desirable products from low quality, low grade and low value timber. The next steps are to increase dissemination and awareness of what the project has shown and to assist those who keen to make a difference to be able to effectively their projects.

Report to March 2004 4 Introduction

The project was conceived to identify infrastructure development opportunities and key examples of best practice in the utilisation of urban timber. The aim was to create the stimulation for further market development for products derived from the resource. The main part of the project carried out a practical evaluation of a number of timber products produced from the urban forest resource. This part of the project was particularly successful as a range of 14 different products were produced from locally sourced timber.

The project also included a thorough investigation of the planning issues that would affect the establishment of timber processing infrastructure and an optimum site location search. Other elements looked at market barriers, funding opportunities and existing examples of timber processing and recycling initiatives.

Dissemination of the work is a key element and is ongoing. A paper has been accepted for the Smallwood 2004 conference and will be presented in May 2004.

The Need for Processing Infrastructure

Both Forests have extensively researched the existing timber supply chains in the sub- region (The Mersey Forest, 1999; University of Salford, 2000). Research showed that the existing timber-processing sector was disparate and did not behave as a cohesive market sector. Very little locally sourced timber was used and it was noted that primary timber processing activities had become almost non-existent in the past 15 years. There are therefore few opportunities to market local timber.

As and woodland management are key strategies within the Community Forests, the lack of markets for timber is a serious concern. Another compounding factor is that low timber prices have reduced the financial viability of most operations to a point where owners maybe unwilling or unable to manage their . Other adverse factors include small woodland size, poor site access, historical lack of management, non-timber management objectives, poor quality timber especially low- grade hardwoods, small diameter trees, poor form, mixed species, undesirable species and vandalism (eg fire or nail damage).

Sustainably managed woodlands bring many benefits such as enhanced biodiversity and improvements to surrounding communities. Everyone can benefit from well managed woodlands. Development of processing infrastructure is critical to encourage the market development that will provide the economic motive for sustainable woodland management.

Report to March 2004 5 Existing Timber Recycling and Processing Initiatives

This section identifies a number of examples of existing companies and initiatives that are currently using or recycling urban timber.

Frankland Tree Services, Altrincham

Established for 18 years and with eight full time staff and four part time staff, this tree contracting organisation undertakes many arboricultural operations in the urban areas of Greater Manchester. Each year, the organisation deals with approximately 250 tonnes of softwood, 500 tonnes of hardwood and 1,250 cubic metres of wood chip. As the company has a strong environmental focus, the aim is to find a use for any recovered timber wherever possible. They believe that they find more positive uses for timber than most similar tree contracting operations in the area.

Where possible any useful wood is sawn and air-dried or treated, then used for a wide range of applications. A mobile saw is rented in on a regular basis for this purpose. Timber is used in a wide range of applications including the construction of quality conservatories, garden sheds, features in school playgrounds, the production of rustic furniture and garden ornamentation, as well as for floorboards and cabinet making. Other material is used for domestic firewood.

A lack of storage facilities was identified as a major barrier for many tree contractors. There is little incentive to invest in rented yards and storage is often too expensive for the periods required for drying. A lack of cost-effective premises can therefore undermine the potential of the operation.

The company has been extremely successful in its endeavours in finding markets for arboricultural arisings. This has also helped to win new customers who may be concerned where the timber goes after it has been cut.

Mersey Valley Warden Service, Chorlton

Mersey Valley Warden Service is funded by Trafford MBC and the City of, Manchester. They manage approximately 50Ha of woodland in Greater Manchester. In recent years they have invested in timber processing equipment including a firewood processor, mobile saw, planer thicknesser and a kiln. They now aim to process the timber that is felled as part of woodland management operations to produce products for use on site, for sale to the general public and to minimise disposal costs.

Key considerations for the investments were gaining political approval and identifying an appropriate site. The site needed to be close to the woodlands, secure and with good access.

Over 90% of the timber they fell now has value added to it. They also take timber generated from other parks in Trafford and Manchester. Longer term plans include trying to expand the current site and looking at adding more value to the material.

Report to March 2004 6 Other Sub-Regional Examples

Various councils, including Liverpool CC and St Helens MBC, attempt to or recycle timber from arboricultural operations. This project has been successful in encouraging other councils to look seriously at what can be done with their timber waste

In terms of recycling and reprocessing timber there is a cluster of large wood recycling companies in the Greater Manchester area. A recent survey for the Waste and Resources Action Programme (WRAP) by TRADA Technology, The Mersey and Red Rose Forests found that a minimum of 163,000 tonnes was received each year by three of these wood recyclers.

Brighton & Hove Wood Recycling Project

It is estimated that up to 30,000 tonnes of waste wood are being landfilled or needlessly burnt in the Brighton and Hove and East Sussex area each year. The Brighton and Hove Wood Recycling Project was launched in February 1998 to collect and find alternative uses for this waste stream by taking a low-tech, low capital intensive approach to wood recycling. The project is established as a not for profit company.

Most of the wood received by the project is collected from construction and demolition sites. A space is allocated on site to store any waste wood and, when the space full, the timber is collected within 48 hours. The project charges 20-30% less than the cost of skip.

Other sources include wooden packaging and broken/non-returnable pallets, plus wood from the domestic waste stream.

Waste wood varies widely in its quality, size and condition. The project sorts timber into 3 basic grades. Grade 1 includes wood good enough to sell back to the DIY/builders market. This includes sound wood of 2 metres or more in length, free from bad splits, nails etc; sheet materials including , chipboard, hardboard and MDF more than 1m2 in area; doors in good condition; and hardwoods and anything “interesting” or “sculptural”. Grade 2 includes timber as grade 1, but in lengths too short for DIY use. Such wood has applications however for making bins, bookshelves, art and craft items etc. Grade 3 represents lower quality material and makes up 80% of the wood waste received, and includes such items as rotten fence posts, small off-cuts and broken doors. It has applications for firewood, and as a for heating greenhouses.

Of the timber collected about 15% is returned to the waste stream. Longer term the aim is to reduce this by actively investigating methods to deal with contaminated wood.

Report to March 2004 7 Existing Markets for Recycled and Virgin Timber

A brief literature review was conducted and the highlights are presented here. There is more of an emphasis on recycling here although there also clear relevance to virgin timber arisings.

Sorting and Classification of Wood Arisings

Wood recycling (DTI, 2001)

Table 1: Categories of wood waste (DTI, 2001) Category Description Recovery options Green waste By-product of the management of trees In situ decomposition, possibly with chipping Untreated wood Mostly untreated packing wood Reuse, recycling, energy recovery Structural wood Construction wood, e.g. railway sleepers, Reuse, limited recycling, and telegraph poles, C&D waste – treated with energy recovery preservatives, etc. Process waste Sawdust, chippings, shavings, etc. Reuse, recycling, energy recovery Waste Products entirely or partly of wood, e.g. Reuse and refurbishment, manufactured furniture recycling, energy recovery products

Wood waste at household recycling centres (AEAT, 2003) A report on wood waste at Household Waste Recycling Centres for Cambridgeshire County Council that included a wood waste sub-category, absent from most other survey work.

Table 2: Wood sub-categories (AEAT, 2003) Category Typical items 1 Melamine Laminated chipboard or MDF, eg white. Includes kitchen units and bedroom units 2 MDF Unlaminated MDF 3 Chipboard Unlaminated chipboard 4 Heavily painted wood 5 Furniture Solid wooden furniture, eg table 6 Wood treated with Fencing posts or panels, shed doors, old front doors preservative 7 Plywood 8 Untreated soft Pallets, DIY off cuts (skirting board, shelving etc.) wood 9 Untreated hard DIY off cuts wood 10 Hardboard 11 Rotten wood

Potential Markets

Report to March 2004 8 Animal bedding (Hadfield, 2003) Like most wood reprocessors, Hadfields Wood Recyclers supply the wood-based panel industry with processed wood chip recovered from mixed wood waste from the commercial waste stream. However, they also process 1,000 to 1,500 tonnes per week of clean packaging wood waste. The finer material from this process goes into compost while the coarser material is put into the £90 million per annum, animal bedding market, as equine bedding/running surfaces and pet bedding.

The equine bedding part of the market already takes some 720 pallets, each of 40 bales, per week. This market is, however, seasonal with demand falling during the summer months when grazing in paddocks is more readily available.

The equine bedding/running surfaces market is a recent development, with a £2 million pound investment leading to a doubling of turnover in each of the last two years (MRW, 2003).

Barriers to Utilisation

Wood recycling (DTI, 2001) Barriers listed include: contamination such as preservatives and the issue of packaging recovery notes (PRN’s) which have skewed the recycled timber market.

Barriers to the recovery and use of recyclable construction waste (APT, 2000) The potential for re-use/recycling is determined by market value, access to markets, quantity available, consistency of quality and attitudinal issues.

Social barriers include: • The need for all parties to understand their role and responsibility towards re- use/recycling • The concept of needs adopting for all producers • Competition and protectionism act as a constraint to the re-use/recycling – co- operation could bring economies of scale and improve viability through the development of partnerships • Lack of awareness about the need to design for , repair and recycling • An ongoing need for education about re-use/recycling

Economic barriers include: • Cost of transport, collection, processing, etc. compared with recyclate values • Need for new, preferably local markets & and development of existing markets • Relatively cheap cost of disposal compared to recycling costs/values – landfill tax is the only indirect financial incentive to encourage any form of sorting/recycling, and it has had an initial impact in reducing disposal to landfill • Need for a differential in collection costs for sorted recyclables – 50% to 75% less than for mixed waste • Lack of incentive to use/no price differential for recycled materials/products in place of virgin materials • No significant preference by consumers – government, industry, public – to buy recycled

Report to March 2004 9 • Many markets for recycled materials/products are small and/or inconsistent • Distance to market

Technical barriers include: • Problems in extracting contaminant, especially from smaller quantities of materials • Failure of waste generators to separate potential recyclates at source – a common problem with C&D waste due to the need to clear a site quickly and the inclusion of a 8-10% margin into the contract price • The need for mandatory sorting/recycling programmes – a survey in the USA showed a 55% recovery rate when mandatory but only 34% when voluntary • Lack of design for waste minimisation, repair and recycling, whether as materials, components or products • The need for R&D to improve product confidence • The lack of a ‘fitness for purpose’ standard to overcome the recycled/virgin material dilema • Limited time and space for sorting skips/operations • High degree of variability in the definitions of different waste material arisings

Political barriers include: • Lack of a legal requirement to recycle (even the Packaging Waste Regulations only require the ‘recovery’ of wood based packaging) • No tax incentives for buying/consuming recycled • Setting of recycling goals without realistic market outlets for the recyclate • Need to introduce/increase minimum recycled content requirements • Landfill Tax needs to be higher so as to be effective in promoting sorting and recycling

An introduction to wood waste in the UK (Magin, 2001) Barriers for local authority wood waste recycling include: • A lack of: local outlets, financial/staff resources, space on site, awareness/information, political will • Contamination/poor quality of material • Logistics/infrastructure • Commitment to existing contracts

Barriers to wood waste recycling by major companies: • A lack of: sorting at source, markets for recycled timber, information/data on markets, space at sites • Contamination/poor quality of material • Charges from specialist reprocessors/prices for recycled wood chip • Capital costs of infrastructure/equipment

Other more general barriers include: • tough regulations/specifications in the construction industry, especially for structural components • inconsistency of supply • mechanised demolition (as opposed to dismantling) • contamination from preservative, glues, metals, wood-based panels • low volume, dispersed arisings and lack of source storage space

Report to March 2004 10 Timber Station Concepts

The concept of a Timber Station can be defined as “a facility that takes timber (from residues to roundwood) and puts it to the most valuable and efficient use. It will provide a mechanism of realising value to the grower, increasing sustainable woodland management, whilst reducing quantities of timber going to landfill.”

A facility could range from a simple small yard through to a large multi hectare site with the latest processing technology. Timber Stations is a concept to encourage the increased use and recycling of urban timber. Infrastructure and attitude are the key barriers to this at present. To increase use and recycling does not necessarily need huge investments. It is often possible to reduce costs by thinking what happens to timber arisings and particularly when linkages are made between timber generated and timber used (and bought in).

Product Development

Product Categories

Products developed as a part of the project are summarised in the table 3. It can be seen that 17 products were produced and these were categorised into 3 broad categories:

Category 1 – Simple products Little more than a mobile saw with a skilled operator required. Products are designed for outdoor use and are rough sawn.

Category 2 – Products using sign making technology It was discovered that that a local sign manufacturer could be persuaded to make a range of products. Process steps were very similar for the different products and the results were very impressive.

Category 3 – More complicated manufacturing processes These were products that were more logistically difficult to manufacture. Some were still relatively simple but more involvement is required to be successful.

Report to March 2004 11 Table 3: Summary of products produced from locally sourced timber No Product Name Timber Source Category 1 – Simple products 1 Path edging Sycamore St Helens 2 Stakes Sycamore St Helens 3 Bird box kits Larch Gtr Manchester 4 Sturdy bench Sycamore/Plane St Helens/Gtr Manchester Category 2 – Products using sign making technology 5 Coasters Sycamore/Cherry St Helens/Gtr Manchester 6 Key rings Beech/Cherry Gtr Manchester 7 Fridge magnets Beech/Cherry Gtr Manchester 8 Name badges Cherry Longford Park 9 Desk names Sycamore Clinkham Wood 10 Cutting boards Beech Longford Park 11 Bread boards Sycamore Clinkham Wood 12 Spatulas Sycamore Clinkham Wood Category 3 – More complication manufacturing processes 13 Stick men Various Widnes 14 Rustic bench Oak Cheshire 15 Simple building Various Gtr Manchester 16 Farm gate Sycamore St Helens 17 Kissing gate Sycamore St Helens

Timber Choice A range of timber species was used in the production of products. Most of this timber was sourced from arboricultural waste or from work in local authority woodlands. It was not considered to be of a quality that could be sold and would in most cases have incurred a disposal cost whether through transport, landfill or the cost of chipping it. Typical logs before and after primary sawing are shown in the figures, below. It can be seen that they show signs of decay and have poor form. Despite this the majority of products made were visually impressive.

Report to March 2004 12 Figure 1: Sycamore logs awaiting conversion in St Helens

Figure 2: Sycamore cants awaiting further processing

Sales

To establish consumer demand for some of the products, they were presented to the general public at events and locations including the Rainford Sidings Lane Rural Craft Fair, Sefton Woodland Fair and Marbury Countryside Fair. The general public were encouraged to make charitable donations for the available products. This enabled the project to establish at what price level people were willing to pay for the products. The project was unable to sell products commercially as there would have been VAT

Report to March 2004 13 issues and it was felt it was beyond the scope of a relatively small project. Average donations made are shown in table 4, below.

Table 4: Typical donations received for wood products at events attended Product Name Timber Typical Donation (£ each) Coasters Sycamore 1.50 Cutting boards Beech 10.00 Bread boards Sycamore 8.00 Bird box kits Larch 10.00 Spatulas Sycamore 2.00

Direct or internal sales will be the key to success with most products. Sales in retail environments are great but if you don’t own the facility then the typical mark-up will either wipe out any profit or make the product uncompetitive for the consumer. It appears that consumers are willing to pay a premium for locally sourced wood products particularly if they are informed of where the timber came from and why it was felled. Forms of direct sale include visitors to site where the products are stored, rural fairs, farmers markets (particularly those in Manchester and Liverpool), website based sales, own retail outlet etc. By selling direct any profit is maximised and it is possible to sell to the consumer in a conductive environment (ie by someone with knowledge of the product and with information about the conversion available).

Manufacturing Process For many of the products (including coasters, key rings, fridge magnets, bread boards and chopping boards) the manufacturing process was very similar. Main process steps included felling trees, sawing timber, drying timber (air or kiln), re-sawing, planing, sanding, cutting (CNC), spray finishing and laser engraving. The figures, below, are from information given to the general public.

Report to March 2004 14 Figure 3: Initial conversion of logs

Report to March 2004 15 Figure 4: Secondary processing of timber

Report to March 2004 16 Product Details

Cat 1 Product Name: Path Edging, Stakes etc

Product Description: Range of rough sawn Sycamore timber for use as path edging, stakes, decking, fence posts etc by Ranger Service. The timber came from local authority woodlands in St Helens. Normally untreated softwood timber would be purchased for this purpose and this is the price comparison used.

Production Process: 1 felling 4 sawing timber 7 final delivery 2 preparation for 5 drying timber (air) sawing/transport 3 transport 6 re-sawing

Timber is stored under cover to dry and is utilised when required. Care has been required with drying as limited air flow has led to mould growth. However, this is not significant and shrinkage/movement has been minimal due to the care used when sawing. Where required, a preservative treatment has been applied prior to use with a brush application. Production Cost: Total cost (inc felling) £3789.94

Retail Cost: Vale of timber if purchased £2022.02 (untreated rough sawn softwood)

Viability: While this may appear to be a loss making operation (-£1767.92) it is interesting to note that transport costs are 65% of the total and in many cases transport would be required to avoid leaving timber on site for whatever disposal option was chosen. If transport costs are removed from then there is a gain of £677.08. Use of local authority timber arisings can be a financially viable option and contributes towards LA21 and sustainable purchasing targets.

Report to March 2004 17 Cat 1 Product Name: Bird Box Kits

Product Description: Simple rough sawn bird box kits made from Greater Manchester larch. Supplied in a mesh bag with all fixings and instructions for assembly. The concept is that these are a more desirable product due to the Community Forest branding.

Production Process: 1 felling 6 re-sawing 2 preparation for sawing 7 transport 3 sawing timber 8 laser engraving 4 transport 9 final delivery 5 drying timber (air or kiln) 10

Production Cost: £3.00 each purchase cost from Mersey Valley Warden Service (MVWS) £1.50 each laser engraving Retail Cost: £10.00 (premium due to the branding)

Viability: These were bought at £3.00 each which is viable for MVWS. The laser engraving is comparatively expensive but does add the ability to brand and therefore command a premium. It could be argued that planing or sanding would make the products more desirable and add little to the costs.

Report to March 2004 18 Cat 1 Product Name: Sturdy Bench

Product Description: These products are benches of varying simplicity manufactured on site using timber from the site in question. The picture on the left shows a more advanced design which requires more time and skill to make. However, it is highly desirable due to its visual appeal. This one is made from Plane. The bench on the left is manufactured from Sycamore. It is a very simple and durable design and is ideal for public sites where there is a risk of vandalism. Due to the large dimensions it is difficult to damage the bench and it would prove very difficult to burn. Production Process: 1 felling 4 assembly 2 preparation for sawing 5 placing in-situ timber 3 sawing timber

Production Cost: £500 for one day demonstration that produces one bench £200 for one days sawing producing enough timber for up to 10 simple benches Retail Cost: Benches can easily cost £500 each. The design on the left could easily attain this price as was proven by members of the general public who offered this much for the product. The price for the simpler design would be less but it is desirable for local authorities with urban sites where benches may be subjected to various abuses by vandals.

Viability: Both designs are financially viable and represent an effective way to use urban timber. The chunky dimensions mean minimal sawing which is efficient and cost effective. Working on site reduces transport cost to a minimum. Obviously using timber from the site is a very cost effective method of providing sustainable seating for that site.

Report to March 2004 19 Cat 1 Product Name: Coasters

Product Description: Drinks coasters manufactured from Sycamore and Cherry. A variety of designs were produced taking full advantage of the flexibility of the laser engraving system. Finished with a lacquer to assist with repelling water and to enhance durability. When given away or demonstrated they came with an interpretive sheet showing how they were made.

Very well received by the general public. A tactile product that many felt was too nice to use as a coaster. People that lived near to where the timber came from found them more desirable probably due to a sense of ownership. Production Process: 1 felling 6 transport 11 sanding 2 preparation for sawing 7 re-sawing 12 spray finishing 3 sawing timber 8 planing 13 laser engraving 4 transport 9 sanding 14 final delivery 5 drying timber (air or kiln) 10 cutting (CNC)

Production Cost: £1.00 each after drying Retail Cost: £1.50 each, discounts for packs of 4 or 6 Competitor products range from <£1.00 to similar prices Viability: At the above costs these have limited commercial viability. However, as an interpretive or promotional product they are very effective at getting the local timber message across.

Report to March 2004 20 Cat 2 Product Name: Key Rings, Fridge Magnets and Badges

Product Description: Cherry, Sycamore and Beech key rings, fridge magnets and badges. The manufacturing process and cost is the same for each product. The shapes are also interchangeable between the products and include triangles, rectangles and ovals. They are finished in the same way as the coaster with a lacquer. They are excellent as an interpretive product because it allows people to see and feel the differences between different timber species.

Production Process: 1 felling 6 transport 11 sanding 2 preparation for sawing 7 re-sawing 12 spray finishing 3 sawing timber 8 planing 13 laser engraving 4 transport 9 sanding 14 fixing magnet/key ring/pin 5 drying timber (air or kiln) 10 cutting (CNC) 15 final delivery

Production Cost: £0.56 each (key rings and fridge magnets)

Retail Cost: £1.00-£1.50 each (based on similar products)

Viability: These appear to be a viable product to produce. They are unlikely to make a profit if sold through commercial outlets but direct sales could be profitable. Like the coasters they are also excellent as an interpretive or promotional product as they are very effective at getting the local timber message across.

Report to March 2004 21 Cat 2 Product Name: Desk Names

Product Description: Desk names were produced from Sycamore for interviews held at The Mersey Forest. The production process was similar to the coasters and the results were impressive.

Production Process: 1 felling 6 transport 11 sanding 2 preparation for sawing 7 re-sawing 12 spray finishing 3 sawing timber 8 planing 13 laser engraving 4 transport 9 sanding 14 final delivery 5 drying timber (air or kiln) 10 cutting (CNC)

Production Cost: £1.00 each plus engraving costs

Retail Cost: £5.00+

Viability: These are desirable items. However, cost is an issue as each different name requires setting up on the laser engraving equipment incurring significant extra costs. There is a premium market for bespoke desk names and there may be opportunities in this.

Report to March 2004 22 Cat 2 Product Name: Cutting Boards

Product Description: Cutting boards produced from Beech. The tree was from Longford Park in Manchester and was blown over, crushing a car. The timber was converted by Mersey Valley Warden Service. Beech is an ideal wood for cutting boards as it is resistant to cutting. It has also traditionally been used for butcher’s chopping blocks with the end-grain facing upwards.

Contact details and the wood description were put on the sides of the product (contrast with the breadboards which were produced first). It was felt this would be more hygienic. Care instructions were supplied to ensure that the products did not warp during use.

Production Process: 1 breakdown of tree 6 transport 11 sanding 2 transport 7 re-sawing 12 laser engraving 3 preparation for sawing 8 planing 13 final delivery 4 sawing timber 9 sanding 5 drying timber (kiln) 10 cutting (CNC) Care is required with quality control (see the section on Quality Issues) Production Cost: £5.00 each after drying

Retail Cost: £10.00 each Competitor products range from £3.00 to £15.00 (and upwards for larger products) Viability: The margin on these is higher and they are perceived to be a useful, desirable product. However they are priced to compete against premium products so quality control is important. Third party retail sale may not be feasible although direct sales to customers would be.

Report to March 2004 23 Cat 2 Product Name: Bread Boards

Product Description: Bread boards were produced using Sycamore from Clinkham Wood in St Helens. Sycamore was traditionally used for kitchen utensils and bread boards because of its fine grain and natural anti-bacterial properties.

Care instructions were supplied to ensure that the products did not warp during use. Some of the boards did suffer from movement. This was due to the thickness of them (~2.5cm) and also the humidity differences between centrally heated homes and offices and the factory where they were produced. It was thought that the logo on the front could be a hygiene issue even though the general public liked the visual effect. Views of the general public on visual defects such as knots varied – some people preferred the products with knots while others preferred those with no defects. Visual defects were not necessarily a deterrent to purchase. Production Process: 1 felling 6 transport 11 sanding 2 preparation for sawing 7 re-sawing 12 laser engraving 3 sawing timber 8 planing 13 final delivery 4 transport 9 sanding 5 drying timber (air or kiln) 10 cutting (CNC) Care is required with quality control (see the section on Quality Issues) Production Cost: £4.80 each after drying

Retail Cost: £8.00-£10.00 each

Viability: The margin on these is higher and they are perceived to be a useful, desirable product. However they are priced to compete against premium products so quality control is important. Third party retail sale may not be feasible although direct sales to customers would be.

Report to March 2004 24 Cat 2 Product Name: Spatulas

Product Description: A simple kitchen spatula made from Sycamore. The design is very basic and in hindsight more thought could have gone into this. Sycamore was traditionally used for kitchen utensils because of its fine grain and natural anti-bacterial properties.

It was thought that the logo on the front could be a hygiene issue even though the general public liked the visual effect. Some quality control issues were encountered particularly with large knots which resulted in weakness. Interestingly, views of the general public on visual defects such as knots varied – some people preferred the products with knots while others preferred those with no defects or character. While defects that lead to product failures are undesirable, visual defects were not necessarily a deterrent to purchase. Production Process: 1 felling 6 transport 11 sanding 2 preparation for sawing 7 re-sawing 13 laser engraving 3 sawing timber 8 planing 14 final delivery 4 transport 9 sanding 5 drying timber (air or kiln) 10 cutting (CNC) Care is required with quality control to reduce the occurrence of weakening defects Production Cost: £2.50 each. This was high when compared to the coasters. The more complex shape was thought to play a part in this as was the 2 position engraving. Retail Cost: £2.00 each

Viability: Production costs were unusually high for the spatulas. When compared to the coasters they appeared to not represent value for money so therefore only an average £2.00 donation was achieved for each one. Therefore these products did not appear at all viable.

Report to March 2004 25 Cat 3 Product Name: Stick Men

Product Description: Stick Men, designed as garden ornaments, produced from a small diameter timber from a number of species. The timber was produced from garden arboricultural operations. The usual disposal options would have been chipping or burning.

Produced in approximately 10 different designs with an escape from the garden theme. Based on similar products that are imported from Holland. The aim was to produce a higher quality themed product from low value timber. Production Process: 1 collection of timber 4 component sawing 7 final delivery (batch) 2 breakdown/sawing 5 assembly 3 storage/drying 6 sanding/finishing The production process is fairly complex due to the need to produce a variety of standard components that are appropriate to a number of final designs. Batch production of the components is the most efficient way to maximise production rather that attempting to build each stick man in one go. Production Cost: Approximately £5.00 each although further studies are required due to the small production run.

Retail Cost: Similar products cost £10.00-£30.00 in garden centres across the region. The products were only displayed but despite this the general public made numerous offers to buy them at similar prices to the above. Viability: These products are highly desirable as demonstrated by the demand from those who saw them. This type of desirability may be relatively short term in nature due to the “faddish” nature of the market. There is potential to produce these products commercially and to streamline the production process to maximise efficiency.

Report to March 2004 26 Cat 3 Product Name: Rustic Bench

Product Description: This bench was produced in cooperation with Cheshire County Council’s Countryside service. They wished to utilise some of their small diameter in the production of a rustic bench. Rustic Wildwood were contracted to produce the bench. The frame is made from Oak and the seat slats are Yew. Timber choice was based on durability and appearance and also on availability. It would be possible to use Oak for the seat slats also.

It is designed for use on public sites where there is little chance of vandalism or for private gardens.

Production Process: 1 felling 4 storage/drying 7 sanding/finishing 2 transport 5 component sawing 8 final delivery 3 breakdown/sawing 6 assembly

As with the stick men the key to efficiency is in effective design, planning and production of the components. This process would be more efficient on a larger production run (rather than one- off).

Production Cost: £100.00 subsidy paid to enable Cheshire CC Countryside Service to commission bench £450.00 paid to contractor Retail Cost: £450.00

Viability: Rustic Wildwood carried this out on a commercial basis so therefore it would appear to be a viable proposition.

Report to March 2004 27 Cat 3 Product Name: Simple Building (Outdoor Classroom)

Product Description: An outdoor classroom was built by Frankland Tree Services in the grounds of the Bollin Valley Primary School. Timber used consisted of arisings from arboricultural operations and included Poplar, Lawson Cypress and Leyland Cypress. Some timber was transported in the round to site and then sawn while some timber was sawn beforehand to allow treatment with wood preservative. The outdoor classroom will be used as an extra teaching space as well as being an educational resource in itself. It will also be used to promote the outdoor classroom concept to other schools and to encourage increased use of arboricultural arisings.

Production Process: 1 felling 4 sawing timber 2 preparation for 5 re-sawing sawing/transport 3 transport of logs and 6 construction sawn timber to site Care is required with quality control Production Cost: £1000 contribution towards costs made.

Retail Cost: £2,000

Viability: This is a viable proposition as Frankland Tree Services plan to offer the outdoor classroom concept to schools. It is an excellent use of arboricultural arisings and also influences tomorrow consumers.

Report to March 2004 28 Cat 3 Product Name: Gates

Product Description: Sycamore was used as the material to manufacture a number of standard farm and smaller kissing gates. The work was carried out at the Centre for Timber Technology and Construction at the Building Research Establishment (BRE). This was very much a demonstration of a “high end” technology led approach to utilisation of urban timber.

Finger jointing technology was used to enable the use of small lengths of timber. This also allowed structural defects in the timber to be removed increasing final product quality. Gate components were preservative treated to enhance durability.

Production Process: 1 felling 6 drying timber (kiln) 11 preservative treatment 2 preparation for 7 re-sawing (where 13 assembly sawing required) 3 transport 8 planing 14 final delivery 4 sawing timber 9 mortising 5 finger jointing 10 sanding The process requires specialist equipment and a certain level of technical knowledge Production Cost: This is dependant on the scale of the operation. Initial investment is relatively high (a finger jointing line is ~£70,000 on top of the requirement for standard saw milling equipment). Retail Cost: These products are designed to compete on an equal basis with standard products and will therefore command a similar price. Viability: Gate manufacture is viable although it needs to be at a scale that is able to recoup the relatively significant capital outlay. It is necessary to assess potential markets and relate this to the timber available. Obviously the lower the quality of the timber the higher the processing cost as more work is required.

Report to March 2004 29 Quality Issues

Due to the costs involved in processing timber for the higher value products it is important that equipment operators are aware of and vigilant towards quality issues. The figure, below, illustrates this point with one of the Beech cutting boards produced.

Significant differential warping makes the product unusable

Cracking

Incomplete planing (flaked timber) due to density differentials

Cracking on 3 knots has led to warping and incomplete planing

Figure 5: Quality issues in Beech cutting board

In this case this particular piece of timber is clearly unsuitable for use as a cutting board so ideally would have been weeded out early on in the process. However, this example actually got through to being laser engraved and was only rejected upon delivery to the project partners. The £5.00 processing cost was therefore wasted and if as with this product run 5-10% of the production contained significant defects then this could have a significant affect on financial viability. There is therefore a need to

Report to March 2004 30 ensure that all operators and sub-contractors all take the same care and understand the quality issues fully.

Funding Opportunities

There are many potential funding streams available. The change in the Landfill Tax Credit Scheme is unfortunate as the concept would have been ideal in category C/CC. If the project were to be high profile, large scale creating significant jobs and financial benefit then organisations such as NWDA, NWRA and Government Office NW may be interested in providing or facilitating funding.

The Objective 1 funding for Merseyside may be one potential source of funds. For processing capacity orientated at virgin timber Measure 10 which is funded by the European Agricultural Guidance and Guarantee Fund (EAGGF) may be suitable. There is over £300,000 available under this Measure. This is managed by The Mersey Forest through a delegated grant scheme. Funding is targeted at both the private and public sectors. Assessment of bids is by the outputs that will be created. Required outputs include creation and safeguarding of jobs and turnover, the creation of new products and the management of woodland. Clearly timber station type projects could meet these outputs.

Other potential sources of funds include the Environment Agency (Multi Functional Projects), Forestry Commission, The Countryside Agency and many trust funds. Private sector sponsorship is one opportunity although the key is in finding selling points that meet corporate social responsibility programmes or mutual ground. Some government training programmes provide opportunities that would allow the possibility of using any facility to deliver training programmes in skills such as , business administration, health and safety etc. Opportunities may be presented by the European Social Fund (ESF), Objective 1 Measure 8B and other New Deal based schemes.

Site and Planning Issues

This work was sub-contracted to TEP. Please see the attached report.

Potential Delivery Mechanisms

Delivery of timber processing infrastructure could be by the public or private sector or both. There are obvious opportunities for any organisation that is creating timber or arboricultural waste to save money and demonstrate best practice in the sustainable management of natural resources and link this to sustainable sourcing. It is clear from the current activity on the ground and the interest that has been shown in the project that increased use and recycling of urban timber is possible. This increase will be driven by enthusiasm although there will also be a need for resources to capitalise on this.

Report to March 2004 31 Dissemination

Dissemination to date is shown in the table below.

Table 5: Dissemination to date Seminar Date Attendees Knowsley Business 24th Sept 2003 22 Environment Club – waste wood meeting Seminar 6th Feb 2004 85 WRAP Seminar 19th Mar 2004 50 TOTAL 157

A paper titled “Creating Products from Small-Diameter Low-Value Logs” has been accepted for presentation at the Smallwood 2004 international conference. A copy of the programme is in the appendix.

Conclusions and Recommendations

The project has shown that it is possible to produce quality saleable products from locally sourced low quality timber. The main points for success are: • assess if you are using timber as well as producing timber waste/arisings • just because a log doesn’t look attractive doesn’t mean it is worthless • the decision to dispose of a log can result in costs meaning a negative cost which has to be a good point to start from if you are producing a product with a positive value • think carefully about what products to make and how much this will cost relative to their value to you or a potential customer • quality control is important is you want to produce desirable products • direct sales to your customers is the best way to make products profitble • the Timber Stations concept has potential in terms of planning and environmental regulations • there are sites out there that are suitable for the development of timber processing infrastructure • some local authorities and tree contractors are already making products to reduce their costs as well as benefiting the environment • lots of interest has been shown in the project

The next steps are to build on the interest shown in the project through further dissemination and facilitation of resources for those organisations with the desire and enthusiasm to utilise urban timber and create value.

Report to March 2004 32 Appendix

Report to March 2004 33