Notes on Computerized Kiln Controls

by
Joseph Denig
Professor and Wood Products Extension Specialist
North Carolina State University

My involvement in computer dry kiln controls dates back to 1984 when I attended an International
Woodworking Fair in Atlanta (the secondary wood manufacturing machine show). One of the nominations
for the Challenger Award was a computerized kiln control. I remember one of the icons of the secondary
wood manufacturing industry running up to one of my friends and asking if he should purchase one of
these machines so he could replace his kiln operator. After the show, North Carolina State University was
given the computerized control to use with their laboratory kilns. The generosity of the vendor was driven
by the idea that the experimental kiln could serve as a test site. The manufacturer’s computer technician
could never figure out drying logic, or maybe we could not figure out his control logic, but needless to say
the manufacturer and the early computerized kiln control passed into oblivion.

We have become a much more mature industry. The major goal in drying should be maintaining an
excellent level of quality and then push production cost lower. We know that a knowledgeable kiln
operator is needed to insure that we get quality and a reasonable kiln through put. With that in mind,
many kiln operators view computerized kiln controls as a tool to help them do a better job.

The following is a list of benefits that can be derived by using computer controls. Not all controls provide
all of the listed benefits, but the list will serve to get your thought process going if you are considering a
new control system and/or kilns.

1. Better monitoring and control of temperature – The electronic sensors used in computerized controls
tend to respond to temperature changes within a kiln faster than the old gas tube sensors. When
coupled with modulating valves (valves that can partially open versus on/off valves) electronic sensors
allow a more precise temperature control in most situations. Other vendors have coupled the on/off
valves with control algorithms (PID) for very accurate and precise control of temperature and
humidity. Computerized controls are better suited for track kilns that have multiple temperature zones
where each zone is controlled by its own valve versus a series of manual controls. Multiple heating
zones can provide more uniform drying by channeling heat energy where it is needed. For example, a
track kiln when first started may be loaded with lumber that has been air dried for several weeks on
one end and freshly sawn material on the other end. With only one zone the entire kiln charge will be
exposed to one set of conditions, largely dependent on where the dry bulb is located. With a multiple
zone system, the zone with the air dried material may reach temperature quickly, closing down the
heat for that zone, while the cooler zone loaded with the green lumber may have its heating valve
open 100 percent because it is not up to temperature.

2. Schedule changes without an operator present – Computerized kiln controls can advance stored kiln
schedules based on time, predicted drying rates or input from remote in kiln probes such as resistance
pins or load cells.

3. Monitor kiln sample moisture content – Depending on the type of system, moisture data from the
lumber load can be monitored either semi-manually or by remote sensors. Three basic systems are:

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 A. Manual – This system can range from the operator manually weighing samples using the oven-
dry sample method and then basing their decision to advance the kiln schedule on this data, to an
electronic scale system tied directly to the kiln control which eliminates the operator having to do
the math and which can advance the kiln schedule automatically. Positive attributes of this system
are: you can get good results in terms of moisture data, it forces the operator to look inside the
kiln, and some automatic advancement of the schedules can be used. Since this system most
nearly duplicates what most kiln operators are currently practicing, it may be the path of least
resistance in terms of technological acceptance by plant personnel. The negative side of this
system is that it does take an operator’s time, thus moisture cannot be continuously monitored.

B. Pin type resistance measurements – Pin type resistance measurements are similar to those that
a pin type electric resistance moisture meter would give. Positive attributes of these systems are:
the moisture can be continuously monitored and the schedule updated. Also the probes can be
stuck in the middle of the lumber stack. Some systems also give shell and core moisture readings
which may be very helpful in drying thick stock. However, above 30 percent and below 6 percent
moisture it is very difficult to get accurate moisture readings from pin type electrical resistance
readings. In some matched sample data I have worked with, the readings from the control were
lower than the actual moisture content at the beginning of drying (about 28% average moisture
content 4/4 white oak) and towards the end, the moisture content displayed by the control was
lower than the actual moisture data. Some vendors have incorporated the use of oven dry samples
in conjunction with their pin type resistance probes to correct the accuracy of the readings at
higher moisture contents.

C. In kiln weight systems – These are load cell systems that continuously weigh the moisture content
samples inside the kiln to give a moisture content reading. The operator still prepares the oven
dry moisture content sections for each sample. In new systems the reliability of the load cells has
greatly increased. Positive attributes of this system are: it continuously tracks the moisture
content of the load, and can continuously advance the schedule. Reported accuracy results by kiln
operators have been good. However, the system does not track the moisture of the inside of the
load.

4. Control fan speed during drying – Variable speed fans can be tied in directly with computer controls.
Fan speed can thus be automatically changed as the schedule is advanced.

5. More information is available to the operator – Graphic displays have made many advances. Some
operators have found many useful ways to utilize this data. Uses have been from evaluating the
progress of conditioning by comparing the dry bulb temperature on each side of the load versus the
wet bulb, to being able to find traps that are stuck open by looking at the percentage a steam valve is
open versus the temperature in a heat zone and comparing this to other zones.

6. Manage steam demand – Steam use can be controlled or prioritized by controlling kiln start up and
conditioning. This may be a very important factor for companies that are boiler constrained and cannot
consider additional boiler capacity.

7. Monitor kiln conditions and shut the kiln down automatically – Parameters can be set up in many
computerized controls to automatically shut down the kiln if the parameter is exceeded. For example,
if the dry bulb goes above a certain temperature, or the wet bulb depression gets too large, the kiln

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 will automatically shut down. Some controls will automatically call the operator (even at midnight)
and alert them if there is a problem.

8. Troubleshoot kiln problems – See Item # 5.

9. Ramp schedule changes – Instead of large step changes as in the traditional Forest Products
Laboratory (FPL) schedules, computerized controls can ramp schedules. Instead of exposing lumber to
rapid equilibrium moisture content (EMC) changes and creating or deepening checks, the changes in
EMC can be slowed.

Some Additional Thoughts Concerning Computerized Kiln Controls.

1. You still need an operator – To use computer controls to their full potential you will need an operator
who has a good understanding of drying. In addition to their kiln drying knowledge, they have to be
willing to learn to use a computer and understand computer logic.

2. You still need to look inside the kiln daily – Continuous moisture readings are only part of the
equation. You need to see if the lumber is mildewing or checking. The concern is not limited to
moisture loss, quality is the number one issue.

3. Sample selection is critical – If you are using some type of continuous moisture monitoring system,
sample selection is just as critical, if not more so, than if you are doing manual samples. If you just pick
dry samples, the computer will not have good data to work from.

4. You must understand how the computer collects and uses data – That includes knowing which
moisture content samples the computer is using to advance the schedule and which is your controlling
dry bulb temperature. Some systems allow the operator to designate on which samples to advance
the kiln schedule. Others can use the average of the wettest half, or wettest three, etc. Also, some
European controls use an average dry bulb temperature while most of our North American schedules
are designed to use the hot side (incoming air side) as the controlling dry bulb temperature.

Many kiln operators use different methods to buffer their kiln schedule advancement. For example, in
a package kiln with low airflow, a kiln operator may stay a step behind in the schedule or use their
wettest sample to avoid raising the temperature before the center of the charge of green red oak is
below thirty percent. The question may be raised, are there any ways to buffer the kiln schedule
advancement with a particular computerized kiln control? Some of these problems can be avoided if
a good pre-drying system is in place.

5. Maintenance is critical – In a manually controlled system, the operator can easily compensate for a
maintenance problem. For example, a steam valve that leaks can be manually shut off. With a
computerized system, the computer cannot shut off the manual valve. Thus, steam bypasses the
control valve and gets into the coils and heat is added to the kiln even though the valves are shown to
be shut off. A situation like this could cause a temperature over-ride during conditioning, resulting in
lumber that is not stress free even though the computer was trying to get the correct dry bulb and wet
bulb temperatures for conditioning.

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6. Computer controls cannot compensate for poor drying practices – Most sawmills that are known for
their drying practices have a drying system in place. That is, they emphasize good sticking and stacking
practices, use shed, fan shed or pre-dryers to avoid drying defects that occur prior to kiln drying, and
have knowledgeable and motivated kiln operators in place.

7. Look at the service and support record of the potential vendor – Do they have a good support record
for their products.

8. The computerized controller should be user friendly – An operator should be able to easily navigate
their way through the system. Kiln data should be presented in an easy to understand manner. The
operator should be able to easily enter or customize drying schedules.

https://sites.cnr.ncsu.edu/wpe/publications/notes-on-computerized-kiln-controls/

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