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Case Studies of Heat Treating and Mold Control of Wood Pallets

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Case Studies of Heat Treating and Mold Control of Wood Pallets
Brian Bond
Department of Wood Science and Forest Products , Virginia Polytechnic Institute and
State University , 1650 Ramble Rd., Blacksburg, VA 24060, email: bbond@vt.edu

Keywords: Pallet, Heat Treatment, Phytosanitation, Mold

ABSTRACT

Trials were conducted to determine treating times, moisture content loss, and pallet
degrade for various heat sterilization techniques for pallets. The results indicate that
while steam treatment is the most rapid and that the wet-bulb depression can affect
treatment times, treatment times where rapid for assembled mixed hardwood stringer
pallets (65-181 minutes) and that pallet degrade was minimal.

Treating times and potential degrade were further investigated through the use of a
commercial heat treatment chamber. The results confirm that for green hardwood pallets,
heat treatment with no humidity control leads to rapid treating times with minimal
degrade. It was noted that recycled and remanufactured pallets did have an increase in
open splits, which can lead to reduced pallet strength.

It was discovered that heated pallet material gives off considerable moisture in short
duration, which can lead to ideal mold growth conditions. Drying the surface of the wood
to 20% moisture content or treating with mildacides are suggested mold prevention
techniques.

INTRODUCTION

The pallet industry is faced with the requirement of sterilizing pallets or pallet parts prior
to export to countries participating in the International Plant Protection Convention
(IPPC). The regulations stipulate that the interior of hardwoods and softwoods used in
pallets and packaging material be heated to 56o Centigrade (oC) or 133o Fahrenheit (oF)
for a minimum of 30 minutes. Each pallet or pallet part must be marked to verify that it
has been heat-treated.

When the IPPC regulations where first announced, little was known about how long the
treatment process would take, what type of degrade would be experienced and what
treating difficulties might arise. To address these issues several tests were conducted in
laboratory kilns and commercial heat treatment chambers. This report describes the
findings of the trials and some of the potential problems with the heat treating methods.
 LABORATORY TRIALS

Several trial runs were conducted in laboratory dry kilns to determine treatment times,
moisture loss and potential pallet degrade using various heat treatment methods on
assembled pallets and dead packed pallet parts. The internal temperature of pallet
material was measured using thermocouples, which were placed in the center mass of the
largest component used. When interpreting the results it is important to consider that
these trials were conducted in a small laboratory kilns (1,000-1,500 board feet capacity)
with a heating capacity of 200,000 to 400,000 Btu’s/mbf/hour. Commercial heat
treatment times may vary due to the rate of heat transfer in the chamber, the initial
moisture content of the wood, the density and sizes of the members treated.

Steam Heat
The initial testing was done using steam heat. It was hypothesized that steam heat would
have the shortest treating time and the minimal amount of degrade since the treatment
was done in a saturated environment. For this test the heating valve of the kiln was shut
off and the wet bulb temperature was set to 160o F. Steam was introduced into the kiln
using the high-pressure steam spray. The wet bulb reached setpoint in 25 to 30 minutes.
The treatment time for mixed hardwood conventional stinger pallets was approximately
65 to 70 minutes and 100 minutes for hardwood block pallets (Denig and Bond, 2003).
Tests using steam for heat sterilization resulted in no moisture content difference between
material measured prior to treating and treated material. No pallet degrade was observed;
however some minor iron staining did occur in oak pallets at the location of the nails.

Table 1. Heat treatment times for mixed hardwood stinger pallets, block pallets and dead
packed pallet parts.
Wet
Bulb
Setting Description Of Product Minutes to sterilize
o
160 F Hardwood 1-1/2" by 3-1/2" stringer pallets 65 to 70
160oF Hardwood 3-1/2" by 2-3/4" by 5" block pallets 100

6" by 5/8" by 47-1/4" poplar deck boards 734

160oF - Stack 36"wide by 47-1/4"long by 41"high
6" by 3-1/2" by 48" red maple pallet cants 933
160oF - Stack 38-1/2"wide by 48"long by 40-1/2"high

6" by 3-1/2" by 48" red maple pallet cants 941

160oF - Stack 38-1/2"wide by 48"long by 40-1/2"high

While these treating times are relatively short, many pallet manufacturers were interested
in maximizing the volume of material that could be heat treated in one charge. Also,
many pallet manufacturers were interested in heat treating pallet components prior to
assembly. Tests on dead packed palletized pallet parts were conducted at North Carolina
State University. These tests determined that it takes 734 to 941 minutes (approximately
16 hours) to heat treat dead packed pallet parts (Denig and Bond, 2003). While this is
approximately fourteen times longer than assembled pallets, the increase in volume of
material in the heat treatment chamber is significant.

Heat treatment with steam does have some potential drawbacks. Steam sterilization of
pallets in under two hours is a relatively energy intensive process compared to normal
hardwood kiln drying. To get the rapid treatment times similar to those in the described
trials, the boiler horsepower needs may be significantly higher than those used in lumber
drying. Also, the water-saturated environment used for heat sterilization can be extremely
corrosive to heat treatment chambers (especially steel and block structures). Red oak and
hemlock are well know for their acetic acid content which in combination with large
amounts of condensation can destroy a kiln rapidly.

Schedules for heat sterilization times based on specific gravity, desired heat treatment
temperature, chamber temperature, and temperature of the member have been developed
for round and rectangular cross sections (Simpson, 2001).

Heat with no humidity control

The next test was conducted to simulate a direct or indirect heat sterilization unit. Heat
was provided using steam heated coils in a laboratory test kiln. The wet bulb was set to
150o F. The steam spray was valved off during this trial. The dry bulb reached setpoint in
20 minutes. It took a total of approximately 80 to 85 minutes for the conventional stringer
pallets to be treated using these conditions, and up to 165 minutes for the block pallets.
Pallets treated with the dry heat schedule exhibited some checks and cracks around the
nails and separation of the deck boards from the stringer due to mild cupping. While no
quantitative measurements were made, the pallet producers supplying the material did not
consider the degrade to be detrimental. Quantitative degrade information for a
commercial heat treatment chamber for different pallet types will be discussed later in
this document. Heating treating schedules for lumber and square stock of Douglas fir and
Ponderosa pine are available from the Forest Products Lab in Madison, WI (Simpson et.
al, 2003).

Heat and humidity control

The third test was done using heat with a 62% relative humidity. By using a higher
humidity it was hypothesized that sterilization times would be reduced since less drying
would take place during treatment. Data from the two previous tests indicate that the
higher humidity air (steaming schedule) the more efficient transfer energy. A dry-bulb
temperature of 180oF and a wet-bulb temperature of 160 oF was used. At total treating
time of 85 minutes was determined. While this test indicates that an increase in humidity
does lead to decreased treatment times, the contribution of humidity to the reduced
treatment time cannot be determined since a higher temperature was used. Simpson
(2002) demonstrated the relationship that increasing the wet bulb depression leads to
increased heat treatment times.
 COMMERCIAL TREATMENT CHAMBER TRIALS

Several trials were conducted with a commercial heat treatment chamber to compare
treating times, potential degrade, and moisture content losses for different types of
pallets. These tests were conducted using a Pest Heat ™ Thermal Pest Management
Chamber No. PH-ID-1. The unit was 101-inches wide, 36-feet long and utilized an
average air velocity through the pallet charge of 300 ft/minute. The heat source was
propane at 400,000 BTU/hour. Trials of kiln dried spruce, pine and fir, green mixed
hardwoods, and repaired and remanufactured pallets were conducted (White and Lamb
2001).

The moisture content of each of the test pallet groups was measured both prior to heat
sterilization and after. The net moisture content loss is recorded in Table 2. Treatment
times varied between 2 hours and 23 mintues to 4 hours and 24 minutes with green
hardwoods requiring the longest treatment times (Table 3). The increased treatment time
for hardwoods was likely caused by the greater initial moisture content of the material.

Table 2. Initial, final and net change in average moisture content fore heat treated pallets.
Test Pallets Initial average MC Final Average MC Net Moisture loss
Green Hardwood 71.6% 63.7% -7.9%
Kiln dried SPF 14.3% 12.2% -2.1 %
Used and repaired 13.9% 12.5% -1.4%

Table 3. Heat sterilization times for each pallet type.

Test Pallets Temp of pallets Time to reach Total Treatment
132.8oF time
SPF 66.4 1 hr. 53 min. 2 hr. 23 min.
Green Hardwood 74.6 3 hr. 54 min 4 hr. 24 min.
Used and repaired 72.2 1 hr. 53 min. 2 hr. 23 min.

Degrade to pallets was determined by the difference in the number of open and closed
splits prior to treatment and after treatment. Open splits are those in which the nail shanks
are visible and closed splits are those in which the shanks are not visible to the naked eye.
Open splits significantly reduce the pallet joint integrity. Closed splits, while they do not
effect pallet performance, may lead to open splits if the wood is exposed to further drying
and shrinkage. The kiln dried pine and green mixed hardwood material resulted in not
significant change in the number of closed splits. Recycled and remanufactured
hardwood pallets were the only group tested where the increased number of closed splits
indicates that humidity control may be required for heat treating. The results of these tests
further indicate that heat sterilization can be accomplished rapidly with minimal degrade
for green hardwood and kiln dried softwood pallets.
Table 4. Comparison of open and closed splits for different pallet types.
Test Pallets Number of open splits Number of Closed Splits
Before After % Change Before After % Change
Green Hardwood 4 4 0 146 229 +57%
Kiln dried SPF 13 13 0 42 43 +2%
Used & repaired 44 50 +14% 202 292 +45
 DIFFICULTIES WITH MOLD

Several pallet companies have experienced increased difficulties with mold due to the
heat sterilization process. The heating of green pallet material leads to an increase in the
rate of moisture evaporation after the material has been removed from the heat treatment
chamber. The warm, saturated wood surface leads to ideal mold growing conditions.
Many customers of heat treated pallets believe that the heat sterilization process not only
eliminates insects in the wood but also prevents mold. While the heat sterilization process
does kill mold, it does not prevent further potential for mold growth. Heat sterilization
can actually lead to ideal mold growing conditions. It is very important the pallet
producers and heat treaters educate their customers in regards to preventing mold growth
during transportation and handling.

Optimal conditions for mold growth include wood surfaces with a moisture content of
twenty-five percent or greater, air temperatures from 66 to 90 degrees F and storage
areas with little to no air movement. To prevent mold it is vital to keep the moisture
content of the surface of wood 20%. This typically means the average moisture content of
the pallet should be in the range of 30-35%. This moisture content must be maintianed
throughout shipping and storage process.

There are many ways to dry the surface of wood down the 20% moisture content. Air-
drying assembled pallets typically take approximately 20 to 60 days depending on the air
temperatures, humidity levels and air-flow. The initial moisture content and specific
gravity of the material also affects the drying rate. To accelerate the drying process a
forced air system could be used. Forced air drying systems similar to fan shed drying
used for “white” lumber can typically reduce air-drying times by one half. Kiln drying
pallets to the average moisture content of 30% can also be done. Trails have shown that
green hardwood pallets can typically be dried to an average of 30% moisture content in
five days with minimal degrade. Kiln drying can also be done in many heat treatment
chambers after the heat sterilization phase; however, venting capacity is required in these
systems.

Chemical treatment can also be used to prevent mold growth on green pallets. Common
mildicides include copper-8-quinolinolate and copper napthanate. Chemical treatment is
typically applied by dipping or spraying the pallets and can prevent mold growth from
one to three months. Chlorine bleach can also be used to remove and prevent mold on
wood. The concentration of chlorine bleach can very greatly and its effectiveness as a
mold preventative is more limited than many copper based chemicals. Many pallet
customers, such as the medical supply industry and the grocery industry, may not be
willing to accept chemically treated pallets.

SUMMARY

The various trials that were conducted to determine treating times, moisture content loss,
pallet degrade and treatment difficulties indicate that there are little differences between
these variables across the different heat sterilization methods studied. While the trials are
 useful for comparing the different heat treatment methods, it should be noted that the
treating times given in this paper are effected by the rate of heat transfer in the kiln, the
initial moisture content of the wood, the density and the sizes of the members.

Treating times and potential degrade were further investigated through the use of a
commercial heat treatment chamber. The results confirmed that for green hardwood
material, heat treatment with no humidity control leads to rapid treating times with
minimal degrade. It was noted that recycled and remanufactured pallets did have an
increase in open splits, which can lead to reduced pallet strength; therefore may require
humidity control during treatment.

Heat treated pallets were discovered to be susceptible to significant mold growth. The
heated pallet material gives off considerable moisture in short duration, which can lead to
ideal mold growth conditions if the material is not handled properly. Chemical treatment
with a mildecide or drying the surface of the pallet material to 20% are suggested mold
prevention techniques.

REFERENCES

Denig, J and B. Bond. 2003. Steam, Dry Heat and Heat with humidity Test Results. Heat
Sterilization Of Hardwood Pallets and Pallet Material. Pallet Phytosanitary Project
Technical Paper No. TP-1 September 2003.

Simpson, W. T., 2001. Heating times for round and rectangular cross sections of wood in
steam. Gen. Tech. Rep. FPL-GTR-130. Madison, WI. USDA, FS, FPL.

Simpson, W. T., 2002. Effect of wet-bulb depression on heat sterilization time of slash
pine lumber. Res. Pap. FPL-RP-604. Madison, WI. USDA, FS, FPL

Simpson, W. T., W. Xiping, S. Verrill. 2003. Heat sterilization time of ponderosa pine
and Douglglas-fir boards and square timbers. Res. Pap.
FPL-RP-607. Madison, WI. USDA, FS, FPL.

White, M. S. and F. M. Lamb. 2002. Performance Evaluation of the Pest-HaetTM Thermal

Pest-Heat TM Management System for the Heat Sterilization of Wood Pallets. William H.
Sardo Jr. Pallet and Container Research Laboratory. Blacksburg, VA.

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