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Forest Friday: Remembering the Roseburg Forest Product (RFP) Missoula Composites facility

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12 May, 2024

This post was originally published on Healthy Forest

Editors note: Kyle Johnson is a forester with the Bureau of Land Management’s Missoula Field Office. Mr. Johnson is not affiliated with Healthy Forests, Healthy Communities but gave us permission to share his message.

Just over a year ago, a group of us from the BLM toured the Roseburg Forest Product (RFP) Missoula Composites facility. It jumped out to me at the time as one of the best tours I’d ever been on because of how clean, organized and efficient the operations were, besides how friendly all the staff were.  Sadly this operation is now in it’s final days and so in recognition of all the folks now unemployed, as well as the outsized impact this will have on our ability to manage Montana’s forests, I give you the Forest Friday I wrote about that tour.  Thanks for reading and have a great Friday.
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Forest Friday: Montana /Dakotas BLM Foresters tour the Roseburg Forest Product (RFP) Missoula Composites facility – originally published 3/3/23
The Missoula Composites operation sits on 200 acres in Missoula, nestled between the train tracks and I-90 near North Reserve Street. The site was originally owned by Louisiana Pacific, and has been in operation since 1968.  Roseburg Forest Products bought the operation in the early 2000’s, and it currently runs 24 hours, 7 days a week. Missoula Composites is a forest product manufacturing site,  but not a sawmill. Rather this site utilizes sawdust from area sawmills, and turns that waste in to valuable and versatile products which is ships nationwide. In years past, Teepee Burners were a common sight at sawmills where all the scraps and sawdust would have been burned. Those days are long gone and today utilization is the name of the game: nothing goes to waste.
The sawdust is sourced from sawmills all over western Montana, such as RY Timber in Livingston MT (Update: now owned by Sun Mountain Lumber), Pyramid Mountain Lumber (update: now closing), and Sun Mountain Lumber in Deer Lodge MT, as well as further afield in NW Montana and Canada. Once at the Missoula site, the sawdust goes through a rigorous process of drying and grinding to make it all uniform within the company’s exacting specifications. The material is then mixed with a binder and spread in a sheet where it is heated and compressed. Next comes trimming to dimension and finishing which includes sanding and/or applying a final white or colored layer for appearance and edging. The finished product is loaded by forklift onto trucks or railcars for distribution across the country. The plant loads out about 4 – 6 railcars and 20 over-the-road trucks everyday. Shelving available at Lowes is the primary market they supply, although more recently they have begun supplying products to more local, independent home improvement stores.
Over the years the RFP company has made large investments to keep the Missoula Composites operation state-of-the-art and a valuable member of the Missoula community such as installing a large earthen berm to stop sawdust from blowing on to neighboring properties and a multi-million dollar “bug farm” which uses natural organisms to clean emissions from the operation. Additionally, the RFP company makes large donations to locally active organizations such as the United Way annually.
The RFP Missoula Composites operation is an excellent example of a modern forest product company making use of what would have been waste in times past. This not only increases the utilization and carbon sequestration of the whole tree, but also reduces emissions from burning wastes. Additionally, by making the sawdust worth a value, it increases the value of the whole process all the way up to the timber sales offered from agencies like the BLM. That increased value comes full circle in helping to sustain and maintain the forest products industry and operators in Montana, which are critical partners in achieving our land management goals.
Our warmest thanks to the staff at RFP Missoula Composites for an excellent tour!

 

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Source: Healthy Forest

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Reaching net zero in the manufacturing sector

Reaching net zero in the manufacturing sector

In order for Australia to reach its goal of net zero by 2050, it needs the help of its manufacturing sector, which accounts for 10% of the nation’s carbon emissions. And the sector is pulling its weight, the Western Sydney Manufacturers Forum heard recently — developing ‘green concrete’, carbon-tracking sensors and technology which can minimise carbon emissions during beer fermentation.

More than 30 experts from universities, industry and government described multiple ways sustainability can deliver real-world impact, cost savings and market differentiation for manufacturers. The forum heard many examples, including an opportunity to reduce emissions from concrete production — which contributes around 8% of global carbon emissions, or more than aviation and shipping combined.

Professor Olivia Mirza from Western Sydney University described the initial pushback to the use of ‘green concrete’ — an eco-friendly alternative which is produced using waste materials — in the Parramatta Light Rail project.

“The initial cost for building [the light rail using green concrete] was let’s say 10 or 12% higher, but then if you do the cost-benefit analysis — less maintenance — it ended up saving 25%,” Mirza said.

The forum highlighted the importance of clear communication and education, suggesting the use of modern formats like social media platform TikTok to effectively engage different stakeholders, especially in the trades, around decarbonisation in building materials.

The aim of the event — hosted by the NSW Smart Sensing Network and the NSW Decarbonisation Innovation Hub at Penrith Panthers — was to showcase opportunities and help manufacturers and their supply chain navigate new emissions reporting requirements.

Dr Martin Ams, a product engineer at Macquarie University, said innovative optical fibre sensors are helping utilities like Sydney Water contribute to net zero by predicting concrete corrosion in wastewater infrastructure.

“Over time, concrete can actually capture and remove CO2 directly from the atmosphere through a process known as carbonation,” he said. “If you have concrete structures that are absorbing CO2 from your atmosphere, you want them to last long so you can keep absorbing this CO2.”

Dr Victor Hernandez Moreno from the UTS Centre for Advanced Manufacturing described how advanced automation and ‘digital twin’ technology can drive more sustainable production decisions for manufacturers. His team operates two mirrored beer-brewing facilities — in Sydney and Germany — that share a unified digital twin, allowing them to analyse data, enhance product quality and reduce carbon emissions.

Keynote speaker and Climate Change Authority Chair Matt Kean said advanced manufacturing in Western Sydney is poised to lead Australia’s decarbonisation efforts by electrifying industrial processes, improving energy efficiency and producing green materials like hydrogen.

“The [Authority’s] Sector Pathways Review revealed that Australia has a great shot at crafting the products, goods and services that will be in high demand,” Kean said. “As the world shifts to net zero, we must be prepared to back our entrepreneurs and innovators and remove policy and regulatory barriers that inhibit progress.”

Kean said products like renewable hydrogen, green ammonia and green metals were essential to reimagining Australian industry. “Importantly, they’re going to be in hot demand, not just domestically, but right across the globe.”

NSW Net Zero Commission principal advisor Manuel Weirich said there is lots of opportunity to reduce emissions in light industry such as manufacturers and smaller processors, which emit 45% of NSW industry emissions.

“These emissions come from things like burning gas in boilers, from engines and motors, chemical processes, calcination in bricks or in cement, and lots of other things,” Weirich said. “Some of the processes are difficult to decarbonise, but others already have solutions available … including heat pumps for water heating, electric forklifts, and better energy efficiency.  

“Manufacturing has a big role to play, to produce the clean materials, the low-emissions materials, and the products and machinery that other sectors use to decarbonise themselves.”

NSW Chief Scientist Hugh Durrant-Whyte said with investment in R&D, skills, digitisation and real-time data, and by preparing for mandatory reporting, Australia can build resilient supply chains and drive sustainable, high-value growth across all business sectors. 

“Digitisation will help identify gaps, improve performance and address skill shortages — especially in hard-to-abate industries,” Durrant-Whyte said. “Achieving net zero will benefit everyone. Small businesses can cut energy costs and preserve expertise through digitisation. Medium businesses can scale up and strengthen supply chains. Large corporations will streamline compliance, meet stakeholder expectations and drive sustainable growth.”

The Executive Director of the Advanced Manufacturing Readiness Facility (AMRF), Ben Kitcher, described how his organisation helps manufacturers adopt technologies that help them become profitable and sustainable.

“What we’re discovering is there is this mutual objective around decarbonisation which always leads back to productivity and profitability,” Kitcher said.

The forum heard that while digital literacy is strong among younger generations, manufacturing still suffers from outdated perceptions. It heard how SMEs in Western Sydney can stay competitive by embracing digital transformation, sustainability and circular economy principles. SMEs are also facing ongoing challenges in resourcing innovation and workforce development, but programs like CSIRO’s Generation STEM are stepping in with practical support through paid internships and university and industry talent matching.

“We have a lot of SMEs that come to us and say their challenge is recruitment and retention, but sometimes we’ve got some SMEs that come to us and say they don’t have the time to do this piece of work,” Generation STEM team leader Luana Caro said.

Chovil & Thake sustainability marketing specialist Hannah Welch said 45% of Australians always or often consider sustainability as part of their purchasing decision-making. She said manufacturers can leverage environmental, social and governance (ESG) data not just for compliance, but as a strategic marketing tool to attract investors and recruit staff.

Andrew Bedrossian, Manager of Renewable Manufacturing at the NSW Department of Climate Change, Energy, the Environment and Water (DCCEEW), said the Net Zero Manufacturing Initiative supports clean technology innovation and low-carbon product manufacturing, with particular focus on revitalising local solar manufacturing. He said there is growing industry appetite and significant investment interest, especially from Western Sydney manufacturers, pointing to strong potential for scale-up and impact.

“We have the world-leading IP here with some of the best brains in the business when it comes to solar,” Bedrosian said. “All the commercial windfalls are offshore. We don’t have anything here, and that’s a real shame. How can we change that?”

Image caption: Climate Change Authority Chair Matt Kean delivered the keynote speech at the Western Sydney Manufacturers Forum. Image credit: AM Visuals.

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