United States 

Department of 

Agriculture

Forest Service

Pacific Northwest 

Research Station

General Technical 

Report

PNW-GTR-820

March 2010

Alaska Birch for EdgeGlued Panel Production— 

Considerations for Wood 

Products Manufacturers

David Nicholls
The Forest Service of the U.S. Department of Agriculture is dedicated to the principle of 

multiple use management of the Nation’s forest resources for sustained yields of wood, 

water, forage, wildlife, and recreation. Through forestry research, cooperation with the 

States and private forest owners, and management of the National Forests and National 

Grasslands, it strives—as directed by Congress—to provide increasingly greater service 

to a growing Nation.

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20250-9410 or call (800) 795-3272 (voice) or (202) 720-6382 (TDD). USDA is an equal 

opportunity provider and employer.

Author

David Nicholls is a forest products technologist, U.S. Department of Agriculture, 

Forest Service, Pacific Northwest Research Station, Alaska Wood Utilization 

Research and Development Center, 204 Siginaka Way, Sitka, AK 99835.

All photos by David Nicholls.
Abstract

Nicholls, David. 2010. Alaska birch for edge-glued panel production—

considerations for wood products manufacturers. Gen. Tech. Rep. 

PNW-GTR-820 Portland, OR: U.S. Department of Agriculture, 

Forest Service, Pacific Northwest Research Station. 25 p.

Edge-glued panels could become a natural extension for the birch (Betula 

papyrifera Marsh.) lumber industry in Alaska, resulting in greater utilization 

of the birch resource while allowing producers to explore a wider variety of 

products and markets. Key advantages of edge-glued panel production include 

the relatively low cost of equipment, the potential use of smaller diameter 

stems and less valuable grades of lumber, flexibility in panel product sizes, and 

opportunities to sell products within established local markets. This paper has 

reviewed practical considerations for wood products firms in Alaska who may 

be considering edge-glued panel production from birch lumber. Key issues 

could include equipment requirements, lumber drying, quality control considerations, wood machining, treatment of character mark features, marketing 

strategies, and strategic partnerships. Edge-glued panels represent a class of 

products that could be within the technical and financial reach of many Alaska 

producers. One immediate opportunity would be kitchen cabinet production; 

however, other products that utilize edge-glued panels include furniture, 

doors, and craft items.

Keywords: Alaska, birch, lumber, edge-glued panel, economic 

development.

Alaska Birch for Edge-Glued Panel Production—Considerations for Wood Products Manufacturers

1

Introduction 

In Alaska, the birch (Betula papyrifera Marsh.) resource is extensive throughout 

parts of the interior and south-central regions of the state. However, relatively little 

birch is sawn into lumber, and much of this is sold into local markets for custom 

projects such as furniture, cabinets, or flooring. Alaska firms currently producing 

birch lumber are generally limited to random-width hardwood lumber, much of 

which is sold to customers at their mill sites. Production of edge-glued panels could 

become a natural extension for the birch lumber industry in Alaska, resulting in 

greater utilization of the birch resource while allowing producers to explore a wider 

variety of products and markets. Key advantages of edge-glued panel production 

include the relatively low cost of equipment, the potential use of smaller diameter 

stems, the use of less valuable grades of lumber, the flexibility in panel product 

sizes, and the opportunities to sell within established local markets. 

Edge-glued panels represent a class of products that is likely to be within the 

technical and financial reach of many Alaska producers. Panels are created from 

narrow strips of lumber that are glued together 

under pressure. Because the finished products 

are often wider than standard lumber, they can 

provide applications that normal lumber could 

not meet. Edge-glued panels are versatile in 

that they can be manufactured for specific 

end uses (e.g., furniture, kitchen cabinets, 

or doors), or made as standard-sized blanks 

(fig. 1) (Bowyer et al. 1986). Because there is 

little specific information for Alaska producers on edge-glued panel manufacture, this 

paper will address some practical aspects of 

production and consider their unique challenges and strategies for success. It follows 

recent research that has considered Alaska 

birch use in retail lumber, cabinets, and craft 

products (Braden and Nicholls 2004, Donovan 

and Nicholls 2003, Nicholls et al. 2004). This 

research found generally high interest in birch 

products among retail managers and consumers in Alaska. Figure 1—Edge-glued panels are often manufactured to standard 

dimensions. These pine panels include high levels of character such as 

knots and grain variation. (Photos by David Nicholls)
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GENERAL TECHNICAL REPORT PNW-GTR-820 

Throughout this paper, “panel” will refer to a finished glued-up assembly. 

“Strips” will refer to the individual pieces that are to be glued together along their 

edge grain. “Lumber” will refer to material that has been sawn from logs, but not 

yet processed into strips.

Birch Lumber Production in Alaska

An estimated 25 sawmills in Alaska have recently processed birch lumber (Parrent 

2004). Current statewide annual birch lumber production is estimated to range 

from 100 to 250 thousand board feet (MBF). Several sawmills produce lumber only 

intermittently, with mills being idle part of the year, and some mills produce both 

hardwood and softwood lumber. At least 19 lumber dry kilns were in operation as 

of early 2005 (Nicholls et al. 2006); however, most kiln facilities (73 percent) dried 

primarily softwood lumber. Most hardwood sawmills are located in the Kenai Peninsula, south-central Alaska (including the Matanuska-Susitna valley), and interior 

Alaska (primarily in or near the Fairbanks-North Star Borough). 

Objectives and Scope

This paper will consider some practical aspects of edge-glued panel production 

from Alaska birch, as well as identify potential barriers. It is intended as a practical resource for wood products producers; it is targeted toward those who already 

manufacture hardwood lumber or hardwood secondary products, and would be 

considering edge-glued panels as a new product line. However, results of this study 

should be of general interest to sawmill owners, secondary product manufacturers, 

and natural resource professionals interested in Alaska birch management and utilization. This paper is not intended as an economic analysis, engineering analysis, or 

business plan, nor does it claim that edge-glued panel production would necessarily 

become a profitable business venture for Alaska firms.

This paper addresses key issues for wood products producers in Alaska, 

including: 

• Resource considerations

• Production process and equipment requirements

• Product yield and product types

• Quality control considerations

• Typical defects in edge-glued panels

• Wood machining and joint preparation

• Dimensional stability

• Wood color
Alaska Birch for Edge-Glued Panel Production—Considerations for Wood Products Manufacturers

3

• Wood strength

• Production levels

• Marketing considerations and strategies

• Strategic partnerships

Key Issues for Alaska Producers

Resource Considerations

Birch saw logs can be obtained from several sources in south-central and interior 

Alaska, including State of Alaska timber sales, land clearings associated with new 

development, and timber salvaged from fire or damaged by other deterioration 

agents. In interior Alaska, the Tanana State Forest has substantial birch resources, 

including more than 1.7 million acres of hardwood forests or spruce (Picea)/hardwood forests. Timber sale schedules are prepared by the State of Alaska Division 

of Forestry, outlining the division’s plans for timber sales (Alaska Department of 

Natural Resources 2009). Actual harvests of birch timber in Alaska are difficult 

to quantify. Further, the distinction between birch fuelwood harvests and birch 

saw-log harvests are often unclear. During 2009, approximately 985,400 ft 3

 of birch 

fuelwood sales were recorded in the Fairbanks area (Hanson 2009). In south-central 

Alaska, two recent timber sales (near Houston, Alaska) totaled 770 cords of birch 

fuelwood (Alaska Department of Natural Resources 2008). Although these harvests 

were designated as birch fuelwood, it is likely that they included some component 

of sawtimber-sized material that could be used to produce lumber for products such 

as edge-glued panels.

Municipal borough land holdings in Alaska can also provide timber for sawmills. In south-central Alaska, the Matanuska-Susitna region (commonly referred to 

as the “Mat-Su” region) is located roughly between Anchorage and Denali National 

Park and has forest stands capable of producing saw-log-sized birch. The Mat-Su 

Borough owns about 365,000 acres of land, of which 66,000 acres is classified as 

commercial forest land (RWS Consulting 2008). Recent urbanization within the 

Mat-Su region has resulted in land clearings for housing and other development. 

Removal of birch trees that span a range of diameters (including some of sawtimber 

size) provides an opportunity to use the resulting logs for value-added products, as 

opposed to hauling them to landfills.
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GENERAL TECHNICAL REPORT PNW-GTR-820 

Equipment Requirements

Many smaller wood products producers in Alaska that are producing lumber may 

already have much of the equipment needed to produce edge-glued panels. For low 

production levels, basic equipment needs could be achieved with the following:

• Sawmill for primary log breakdown

• Lumber dry kiln

• Planer 

• Jointer

• Rip saw

• Chop (cross-cut) saw

• Glue-mixing and application equipment

• Clamp carrier or other clamping equipment

• Abrasive sander

• Banding and packaging equipment (if needed)

• Dry storage facility

• Moulder (not required, but could replace several equipment items above)

Several equipment combinations are possible from the list above. One producer 

indicates that very good results are achieved when producing groups of four large 

panels (up to 12 ft by 30 in) in batches, using stationary clamps, but without the 

need for automated clamp carriers (Poppert 2009). Other strategies could be used to 

allow firms to start producing panels with even simpler overall equipment requirements. For example, lumber could be purchased from outside vendors, eliminating 

the need for a sawmill and a dry kiln. Firms wishing to increase production levels 

of edge-glued panels could use this arrangement to produce exclusively panels (but 

not lumber).

For most firms already producing lumber, an important consideration (and 

possible learning curve) would be the addition of gluing and clamping equipment. 

Other important considerations would be whether to produce fixed-width versus 

variable-width strips, and what strip thickness would be optimal (i.e., could thinner 

strips be used for certain applications?). This decision could have implications for 

many later stages of the process, including stacking, sorting, and lay-up operations. 

Another aspect of the learning curve is that by producing new products such as 

edge-glued panels, firms have an opportunity to “become the customer.” That is, 

when they use material in a secondary process that they have already produced in a 

primary process (i.e., lumber), they can become aware of previously unrecognized 

quality issues.
Alaska Birch for Edge-Glued Panel Production—Considerations for Wood Products Manufacturers

5

Product Yield and Product Types

An important consideration for edge-glued panel producers will be the relative 

importance of panels versus other products in their portfolios (such as lumber, craft 

products, or energy products). A natural arrangement could be for wider and higher 

quality boards to be used for lumber, with narrower and lower grade boards (strips) 

for edge-glued panel production. Even smaller cuttings could be used for craft products or wood energy (along with sawdust and other residues). It is often desirable to 

limit the width of individual strips within edge-glued panels to a maximum of 3 in, 

as wider strips could be more likely to warp under changing moisture conditions. 

However, the use of many narrow strips in a glued panel results in greater glue use 

(and cost).

Another important consideration influencing yield would be whether lumber 

is ripped or cross-cut first. In high-production settings, lumber can be cross-cut 

to its longest usable length, and then further cut to one of 12 standard lengths 

(Araman and Hansen 1983). For smaller producers, fewer standard lengths would 

be recommended. Here, material could be processed first on a table saw (ripping), 

and then on a chop saw (cross-cutting), to achieve the desired length and width 

distribution. Simple guides and stops can be used with chop saws to ensure good 

length consistency for all material within a given length class. At higher production 

levels, finger-jointing equipment is commonly used to produce material to specific 

lengths with minimum waste. Accurate processing of lumber at this point (both 

width and length) will also help minimize trim losses after panels are glued.

Buehlmann et al. (1998, 1999) compared yields of red oak (Quercus rubra L.) 

lumber using computer simulations to evaluate “rip-first” versus “cross-cut-first” 

sawing strategies. Rip-first sawing resulted in generally greater yields than crosscut first; however, significant differences were noted only when character marks 

less than 1-in diameter were considered.

Whether or not character-markings are included (versus clear wood only) in 

finished products has an important bearing on overall yield and value. For example, 

in one study that considered 2.782 MBF of birch lumber from Fairbanks and 

Anchorage, Alaska, the inclusion of small (0.5 in) character marks in lumber 

resulted in lumber value increases of $138 per MBF (Nicholls et al. 2004). 

Buehlmann et al. (1998) found that product yields were influenced by the size 

of the character marks allowed, the type of character, the grade distribution of 

the original lumber, and whether board grades are based on one or both faces. 

Here it is important for producers to understand customer needs—for example, 

whether panels will be used in applications where only one side is visible (i.e., 

certain types of furniture) versus panels having two appearance faces.
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GENERAL TECHNICAL REPORT PNW-GTR-820 

Quality Control Considerations

Quality control considerations are important during all phases of production including lumber processing, drying, gluing, panel trimming, and sanding. Several factors 

should be considered by manufacturers to ensure consistent quality of edge-glued 

panels.

Clamping pressure—

Clamping pressure is needed for close contact between wood surfaces and the glue. 

The optimal clamping pressure depends on wood density. Clamping pressures for 

birch (an intermediate density wood) would range from 150 to 200 pounds per 

square inch (psi). This is intermediate between high-density species (e.g., red oak) 

requiring 200 to 250 psi, and low-density species (e.g., spruce) needing only 100 to 

150 psi (River and Okkonen 1991).

Glue consistency—

River and Okkonen (1991) identified several factors influencing bond formation in 

glued joints:

• Glue formulation (including molecular weight and solids content)

• Storage time of glue prior to use

• Spreading rate of glue on wood

• Air humidity in the gluing room

• Wood moisture content

• Temperature of both wood and air

• Assembly time

Wood moisture content—

Wood moisture content can have an important effect on gluing properties and on 

the dimensional stability of panels in service. It is important to kiln-dry all wood to 

a moisture content close to the end use conditions (6 to 8 percent moisture content is 

recommended for much of the United States [Forbes 1997]). However, in very cold, 

dry regions (such as interior Alaska) moisture contents of less than 6 percent might 

be needed to reduce or eliminate shrinkage. 

Wood, glue, and air temperature—

The temperature of wood, glue, and air can influence glue curing times, and 

therefore it is important to follow glue manufacturer recommendations. In cold 

shops during winter, glue curing can take up to twice as long as during summer 

temperatures (The James L. Taylor Companies 2008). It is important to do all 

gluing at room temperature, allowing wood to first reach equilibrium moisture 

content (EMC). If lumber is stored outdoors, or in an unheated area, it should be 
Alaska Birch for Edge-Glued Panel Production—Considerations for Wood Products Manufacturers

7

moved into a heated shop before gluing takes place (and sufficient time should be 

allowed for wood to reach room temperature). This could be especially important 

during winter production in interior Alaska, where temperatures below freezing are 

common.

Strip widths—

Use of narrower strips will help minimize cupping (which can be a problem when 

using wider pieces). A maximum strip width of 3 in is generally recommended; narrower (and thus more) strips means more glue lines and also greater glue expense. 

In practice, these two conditions would need to be balanced against one another.

Strips should be selected to minimize the amount lost in trimming to final size. 

For example, a wide strip should not be included along the edge of a panel if it will 

generate excessive waste during edge trimming. If possible, strip widths should be 

selected so that less than 0.125 in of trimming is necessary to reach the final panel 

width (Mitchell et al. 2005). However, in practice a trim allowance of greater than 

0.125 in may be necessary.

Grain orientation of adjacent strips—

Adjacent strips should have growth rings oriented in opposite directions (i.e., rings 

cupped up versus rings cupped down). This way each strip will help restrain the one 

next to it if moisture changes are encountered.

Typical Defects in Edge-Glued Panels

Most defects in edge-glued panels can be classified as those related to moisture content changes, wood machining, or operator decisions. Defects can be detected either 

during processing or when products are in service. Typical defects are described 

here.

Delaminations—

Many times, delaminations can go unnoticed in fine-textured woods because 

failed surfaces can feel smooth to the touch (River and Okkonen 1991). If the wood 

becomes dryer while in service, it is possible for visible delaminations to form as 

the wood shrinks in response to lower moisture content. Conversely, strips having 

too high a moisture content can also lead to delaminations, as well as influencing 

the EMC of adjacent strips (Forbes 1997). Here, high moisture levels can interfere 

with the integrity of wood-glue bonds.

Wood loses or gains moisture about 10 to 15 times faster through the end grain 

versus face or edge grain. Therefore, dimensional change at the ends of strips may 

be more rapid than in the central portion, even for glued-up panels (River and 
8

GENERAL TECHNICAL REPORT PNW-GTR-820 

Okkonen 1991). These more rapid dimensional changes can lead to weak glue lines 

and possible delaminations at the exposed ends of strips in an edge-glued panel.

Cupping—

Cupping, or warping, can be caused when too much of the panel is composed of 

flat-sawn or quarter-sawn strips, and the panel experiences a moisture content 

change. The direction of annual rings should be alternated in adjacent strips to create a balanced panel construction (Mitchell et al. 2005). This way, the tendency for 

a given strip to cup in one direction could be offset (i.e., restrained) by an adjacent 

strip trying to cup in the opposite direction (fig. 2). Having individual strips that are 

too wide can also lead to cupping. 

Figure 2—Panel warpage can be controlled when growth rings in adjacent strips are oriented in random directions, as seen in this 

edge-glued panel from birch.

Wood-related machining defects—

Dull sawblades can create several types of wood defects including (1) visibly 

burned wood surfaces (from excessive heat), (2) a smooth lustrous sheen, or 

(3) a fuzzy grain resulting from incomplete cutting of tension wood fibers 

(Mitchell et al. 2005).

Poor matching of color or grain—

This is an appearance defect caused when dissimilar strips are placed side by side 

in a panel (see “Wood Color” section). When color matching Alaska birch, one 

approach that could be used is to separate “brightwood” from the darker wood that 

is characterized by natural staining (fig. 3). Because the grain pattern in Alaska 

birch is typically less distinct than in some of the ring-porous hardwoods (e.g., red 

oak), sorting by grain would most likely not be a high priority. 

Sunken glue joints—

“Sunken” glue joints can occur, primarily with water-based glues, when the wood 

near a glue line swells more than wood farther away. If the wood is planed in this 

condition, the eventual shrinkage near the glue line can result in a small “valley” or 

recessed area. A solution to this problem is to not machine wood immediately after 

gluing (but rather wait until the wood and glue equilibrate).
Alaska Birch for Edge-Glued Panel Production—Considerations for Wood Products Manufacturers

9

Sunken (or raised) strips—

When strips of different moisture contents are assembled into a panel, a sunken 

(or raised strip) can result. Here, individual strips can shrink or swell at different 

rates (in thickness) as a panel equilibrates, resulting in an uneven surface or rippled 

appearance. It is recommended that all strips be within about 2 percent moisture 

content of each other when glued (Mitchell et al. 2005).

Wood Machining and Joint Preparation

When producing edge-glued panels, uniformly square edges are critical to ensure 

good glue penetration and bonding. Although this can be accomplished using a 

production moulder, most Alaska producers could manufacture small amounts of 

high-quality material using a table saw or jointer. Regions of wood with lots of 

character marks or surface irregularities should be removed.

Poorly maintained equipment can create poor bonding surfaces. For example, 

dull or vibrating cutting tools can loosen wood fibers, leaving wood surfaces less 

receptive to glue (The James L. Taylor Companies 2008). When knives become 

worn and rounded off, they can beat down surface fibers, rather than cutting them 

cleanly. In extreme cases, wood can turn dark from burn marks, and glue penetration is inhibited.

Figure 3—An edge-glued panel constructed from birch lumber containing knots and natural stain.
10

GENERAL TECHNICAL REPORT PNW-GTR-820 

Dimensional Stability

Dimensional stability of panels can be a concern if the EMC of wood when in use 

is different from the wood moisture content at the time of manufacture. Lumber for 

edge-glued panels used as furniture stock is typically maintained at 6 to 8 percent 

moisture content. In Alaska, an important consideration would be to match the 

final moisture of kiln-dried lumber with end-use conditions of panels (whether for 

in-state or export markets). 

Shrink wrapping is often used for higher grades of edge-glued panels. Shrink 

wrapping is useful for protecting panels prior to use. However, this is a temporary 

barrier and would not be effective for reducing dimensional change in use (i.e., 

after shrink wrapping is removed). Panels that are manufactured at a relatively high 

moisture content, shrink wrapped, and then placed in service in arid climates could 

experience shrinkage.

Dimensional stability can also be influenced by the log size and the presence of 

juvenile wood. Serrano and Cassens (1998) found that dimensional change across 

the width of edge-glued panels was significantly higher for panels made from 

small-diameter logs (versus larger stems). However, from a practical standpoint, 

this difference amounted to less than 0.05 in. “Alaska paper birch” has published 

shrinkage values of 6.5 percent in the radial direction and 9.9 percent in the tangential direction (USDA FS 1999). Because these values are based on shrinkage from 

the green condition to oven-dry moisture, they represent the maximum amount of 

shrinkage possible. In practice, panels undergoing moisture content changes of just 

a few percent would experience much less shrinkage.

Wood Color

Color uniformity can have an important influence on product value in edge-glued 

panels, especially when light-colored woods are treated with natural finishes or 

light stains (Comers et al. 1996). A successful color-sorting system must be easy 

to use by plant personnel, must accurately classify parts by color class, and must 

keep up with plant production (Kline et al. 1997). Current trends have called for 

better color matching of individual laminates in panels, especially for export 

markets (Phelps et al. 1994). Both color and grain orientation have been identified 

as important appearance features in white oak (Quercus alba L.) dimension stock 

(Stokke et al. 1995). Other research in Anchorage and Fairbanks, Alaska, has 

indicated preferences for edge-glued panels or cabinet doors having wide variations 

in appearance, including features such as knots and natural stain (Donovan and 

Nicholls 2003). 
Alaska Birch for Edge-Glued Panel Production—Considerations for Wood Products Manufacturers

11

Small producers in Alaska would likely not invest in automatic color-sorting 

systems. Therefore, it would be important to train one (or a few) operators to maintain consistent quality. One approach that could be used would be to use a visual 

preliminary sort into just two categories of strips (e.g., light color versus darker 

color) (Pugel et al. 1995). This would be followed by a secondary sorting step in 

which strips from a given color class (i.e., lighter or darker) would be laid-up into 

individual panels. This secondary sorting step would represent a “fine-tuning” step, 

so that color variation between individual strips in a panel would be minimized. 

It was recommended to include waist-high sorting tables and good lighting that 

includes a mixture of fluorescent and incandescent light (Pugel et al. 1995). Producers of Alaska birch could consider the above approach to sort strips by color, by 

character marks, by natural stain, or other features. 

Another approach that could be used would be to segregate all strips from a 

given log, and then attempt to match individual strips together to form custom color 

patterns or grain patterns. Although this approach could be more time consuming 

(versus no sorting), small-diameter birch logs would generate relatively few strips to 

track. Recent market research in Fairbanks, Alaska, (Nicholls et al., n.d.) has shown 

that consumers can have strong preferences for birch panels having distinctive patterns of natural stain adjacent to clear wood. For markets like these, sorting step(s) 

could prove profitable.

Whether computerized or manual color sorting is used, both sides of a given 

strip should be inspected, and an appearance side assigned. Once this is done, it 

would be important to keep track of the appearance face throughout the manufacturing process. Optionally, strips could be assigned positions within panels (e.g., 

when a specific look is desired). This could be important when creating custom 

panels from Alaska birch that includes high levels of stain, knots, and other features 

(figs. 3 and 4). 

Wood Strength

For most hardwood panels, appearance and not strength would likely be the most 

important consideration (e.g., kitchen cabinets). However, for other applications 

such as furniture stock, strength could be a consideration, and the final product 

design should take this into account. Clamping pressures ranging up to 150 psi 

are typical during resin curing (The James L. Taylor Companies 2008), and this 

pressure is well below the crushing strength of paper birch.1

 When gluing strips 

1 The Wood Handbook (USDA FS 1999) lists the compression strength perpendicular to 

the grain for clear paper birch wood at 12 percent moisture content to be 4,100 kilopascals 

(kPa), equivalent to 594.7 pounds per square inch (psi).
12

GENERAL TECHNICAL REPORT PNW-GTR-820 

containing character features such as knots and bark pockets, it would be important 

to consider that their strength properties could be less than those of clear wood.

Production Levels

Edge-glued panels can be produced on a “factory scale,” with one or two shifts 

per day, sophisticated gluing and clamping equipment, and initial investments of 

several million dollars. Deaver (2006) considered the economic feasibility of a 

plant producing 3.5 million board feet of panels per year in North Carolina, and 

concluded that this would be out of reach for most startup companies. Under certain 

designs, as much as 10 MBF of edge-glued blanks could be produced per 8-hour 

shift, with 38 full-time employees (Araman and Hansen 1983). By contrast, in 

Alaska, neither production capability nor statewide markets would likely justify this 

level of investment because most (if not all) birch sawmills are either sole proprietors or are family run. Resource availability and quality would also be considerations in determining plant capacity.

Most hardwood sawmills in Alaska operate on less than a full-time basis. 

Often, other activities, including timber harvesting, and even nonforestry activities 

(such as commercial fishing) occupy the mill owner’s time. Further, many of these 

Figure 4—An edge-glued panel constructed from birch lumber containing knots as the 

primary character feature. 
Alaska Birch for Edge-Glued Panel Production—Considerations for Wood Products Manufacturers

13

sawmills produce a combination of hardwood and softwood lumber. Therefore, the 

actual amount of hardwood lumber produced in a given year is typically considerably less than the rated sawmill capacity. An important question for these producers 

would be whether their production level would justify the investment in edge-gluing 

equipment (including gluing and clamping) as well as any wood processing equipment not already owned. 

For Alaska producers of edge-glued panels, optimum production levels will 

likely depend on local markets, and on competing (or complementary) hardwood 

products produced by the same producers (or locally). This production level would 

most likely justify only a simple set of stationary clamps, or a small mechanized 

clamp carrier (but not more sophisticated arrangements).

Marketing Considerations

Marketing strategies will become an important part of panel producers’ business 

plans. When developing effective marketing strategies, edge-glued panel producers 

should have a clear definition of their target markets, which takes into consideration 

potential customers, appearance attributes of products, preferred sales outlets, and 

transportation distances. 

Character-Marked Woods

An important consideration for birch panels will be the use of character-marked 

wood (i.e., lumber containing small knots, bark pockets, natural stain, and other 

features not found in clear wood). Birch lumber inventories were evaluated at four 

sawmills in Fairbanks and Wasilla, Alaska. According to National Hardwood Lumber Association (NHLA) rules, only 4.7 percent was in high-grade lumber (Select 

grade or better), with the remaining lumber falling within the Common grades 

(Nicholls et al. 2004). Therefore, producers who wish to fully utilize their birch 

lumber when producing panels would need to include character-marked features 

(and be able to successfully market panels with this “look”). In a separate study, 

600 birch trees from Alaska’s Susitna River Valley were dissected, and it was found 

that 90 percent contained some decay and virtually all trees included at least some 

natural stain (Trummer 2001). Character mark features common to Alaska birch 

include regions of knots (fig. 4), natural stain (figs. 3, 5, 6, and 7), heartrot (fig. 7), 

and decay (fig. 7), a condition that often results in a spalted2

 appearance. 

2 Spalting is caused by certain white-rot decay fungi found primarily in hardwoods (including 

birch) and can result in decorative patterns. The fungi create distinctive zone lines in the wood 

as well as unusual colorations and multicolored streaks. In some cases, spalting can diminish 

wood strength (USDA FS 2004).
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GENERAL TECHNICAL REPORT PNW-GTR-820 

Figure 5—Sawn birch lumber, with regions of natural stain evident on end grain. 

Figure 6—Alaska birch lumber is often characterized by high levels of character, such as 

this stack of kiln-dried, planed lumber at a retail sales outlet. 
Alaska Birch for Edge-Glued Panel Production—Considerations for Wood Products Manufacturers

15

Character-marked birch panels featuring natural stain and knots have demonstrated strong appeal among some homeowners (Nicholls et al., n.d.). The panel 

shown in figure 3 was preferred by a wide margin among home show attendees in 

Fairbanks, Alaska. Many respondents commented on how the natural stain formed 

a striped pattern, often described as a “hickory look.” Thus, one strategy for Alaska 

producers would be to emulate more popular (or valuable) species in edge-glued 

panel construction.

Paint-Grade Versus Stain-Grade Panels

Lower grades of wood could be used for paint-grade panels. Here, the original 

appearance would be completely covered, and as long as the wood surface is 

smooth and integral, consumers would not be able to discern use of lower grade 

wood. 

By contrast, higher grades of wood could be used for stain-grade panels. Here, 

the wood would be treated with a stain or clear coat finish for its end use. Depending on the type of stain used, character marks and other features would still be 

Figure 7—Birch stems can be characterized by regions of (A) natural stain, (B) decay, (C) checking 

and splitting, and (D) bark pockets. Although these features can add to the natural character of this 

wood, they can also reduce lumber recovery. 

A

B

C

D
16

GENERAL TECHNICAL REPORT PNW-GTR-820 

discernable. Past research on red alder (Alnus rubra Bong.) edge-glued panels 

(constructed as kitchen cabinets) found the darkness or lightness of stain can 

have a strong influence on consumer preferences (Nicholls and Roos 2006).

Potential Niche Markets

Niche marketing is a “method for reducing competition and gaining more control 

over product prices” (Smith et al. 2008). Because there is less competition within 

niche markets, the demand for niche products is less elastic, and producers can 

become “price makers.” If the producer raises prices there will be a less-thanproportional fall in the quantity demanded, the result being an increase in total 

revenues.

Smith et al. (2008) identified four major factors to consider when entering niche 

markets: (1) customer perceptions, (2) effect on manufacturing, (3) commitment, 

and (4) markets and marketing. Therefore, an important decision for panel producers in Alaska would be whether to produce and market standard edge-glued blanks 

versus “niche” products to serve specialized markets and customers. Examples 

of niche products could include kitchen cabinets, cutting boards (fig. 8), tabletop 

rounds (fig. 9), stair treads (fig. 10), countertops, and even gift products. 

Figure 8—Edge-glued Alaska birch can be used to make craft products, such as this cutting 

board. Character-mark features visible above include a thin region of natural stain, a knot, and 

grain variation.
Alaska Birch for Edge-Glued Panel Production—Considerations for Wood Products Manufacturers

17

Figure 9—Tabletops can be made from edge-glued panels, and at 

least one major wood products firm markets these items nationally.

Figure 10—Stair treads are a high-value product that can include edge-glued 

lumber. Above, oak edge-glued laminates are enclosed in thin veneers, which 

form the top and bottom surfaces.
18

GENERAL TECHNICAL REPORT PNW-GTR-820 

Several examples of successful niche markets for edge-glued products are 

noted for national and for Alaska markets.

Plum Creek Timber 3

— 

Edge-glued products include paint-grade panels, stain-grade panels, and tabletop 

rounds (Plum Creek 2009) (fig. 9). Higher grades of panels (i.e., stain grade) are 

often shrink wrapped, and are free of finger joints. These panels are identified as 

being suitable for fine furniture applications. Lower grades of wood are often used 

to produce panels that are not shrink wrapped, and may include finger joints. These 

panels are identified as being suitable for crafts and construction projects. 

Poppert Milling (Wasilla, Alaska)—

This firm produces custom edge-glued panels from birch lumber sawn onsite. Two 

classes of products are made: stair treads and glu-lam “beam-wraps.” Beam wraps 

are edge-glued products that are attached to glu-lam beams in interior applications 

for aesthetic reasons (i.e., they are appearance products only).

Five steps have been identified for wood products producers to consider in 

identifying niche opportunities (Smith et al. 2008):

1. Analyze the existing market.

2. Identify neglected or underserved market segments.

3. Evaluate your strengths in serving identified segments.

4. Select the niche where you have a competitive advantage.

5. Develop a marketing program to meet the needs of this market.

For higher value products (e.g., appearance grade birch), producers would need 

to accurately identify and define their niche to avoid direct competition with lower 

value products (e.g., paint grade western pines (Pinus)). Bush et al. (1991) identified 

the tendency of smaller firms to be production oriented with only limited relations 

with end users. These firms might not be fully aware of consumer preferences, and 

thus an “extra effort” is required to accurately define their target markets (including 

niche markets). If firms are successful at entering and establishing niche markets, 

then competition will soon follow from other producers (Smith et al. 2008) (i.e., a 

good idea will not be kept a secret for very long). 

3 The use of trade or firm names in this publication is for reader information and does not 

imply endorsement by the U.S. Department of Agriculture of any product or service.
Alaska Birch for Edge-Glued Panel Production—Considerations for Wood Products Manufacturers

19

Strategic Partnerships

An important aspect of successful marketing of edge-glued panels will be developing partnerships with other businesses involved in the entire supply chain. This 

group could include retailers, distributors, architects, builders, and secondary 

wood products producers. 

A key relationship would be with retail sales managers. Several Alaska retail 

lumber managers have expressed a general interest in carrying birch lumber 

products but stressed the need for a reliable lumber supply (Nicholls 2001). Other 

retailers in Alaska indicated generally strong interest in carrying birch edge-glued 

panels having various levels of character marks, and favored larger panel sizes 

(Nicholls et al. 2010). Brinberg et al. (2007) also found that retailers and consumers 

can value character-marked lumber differently when used in furniture production. 

Edge-glued panels could be produced as dimension stock and then sold to 

producers of furniture, stair treads, and other products utilizing edge-glued construction. As of the mid-1990s, it was estimated that more than 16 percent of dimension lumber was manufactured into edge-glued panels (Smith and Araman 1997). 

Alternatively, edge-glued panels could be sold in standard sizes for home hobbyists 

(i.e., “do-it-yourselfers”). Panels would be manufactured to a set number of standard 

sizes, and sold at lumber yards and home improvement centers (Bowyer et al. 1986). 

Product location, type of display, and whether to shrink-wrap package the panels 

would be important considerations. Again, the relationship with retail store managers would be of primary importance.

Discussion and Considerations

This paper considers production of edge-glued panels as an opportunity for wood 

products firms in Alaska. Important considerations include the scale of operation, 

equipment needs, proper moisture content control, transportation distances, and 

identification of appropriate niche markets. An easily overlooked, yet potentially 

important consideration, would be for heated space for production facilities, especially during winter months. 

Edge-glued panels could become a profitable product line for sawmills already 

processing hardwood lumber that have identified local markets. In some cases, 

edge-glued panels could be substituted for random-width hardwood lumber. Where 

other forest products industries are present (i.e., pellet mills, sawmills, or secondary 

processing firms), edge-glued panel production could experience a synergistic effect 

when becoming part of a local wood products “cluster.” A cluster can be thought of 

as a critical mass of companies in a particular location (Porter 1990, as referenced 

in Rojas 2007). In general, greater local forest products activity could bode well 
20

GENERAL TECHNICAL REPORT PNW-GTR-820 

Figure 11—A kitchen cabinet constructed from edgeglued Alaska birch, featuring bark pockets and natural 

stain. 

for edge-glued panel producers, as it would likely increase their options for buying 

logs or lumber, selling wood waste, or finding markets for slabs and edgings. Plans 

for a wood pellet production facility near Fairbanks, Alaska, have been announced 

(Mowry 2009), but as of 2009, this plant was not yet operating.

Kitchen cabinets (fig. 11) represent the best near-term market for edge-glued 

panel producers for most Alaska markets. They are relatively easy to produce 

(compared to most furniture products), and their small size is favorable for shipping. Narrow board widths in cabinets would be conducive to using small-diameter 

birch logs. Local markets are already well developed in Alaska’s larger cities 

including Anchorage, Fairbanks, Juneau, and the northern Kenai Peninsula. There 

is a strong overall interest in character-marked birch cabinets, as demonstrated by 

consumer preference research in several Alaska markets. Ultimately, it would be 

up to each wood products firm to evaluate the specific resources, production needs, 

and markets that they would serve. 
Alaska Birch for Edge-Glued Panel Production—Considerations for Wood Products Manufacturers

21

Glossary

board foot—A piece of lumber that is 1 ft wide, 1 ft long, and 1 in thick, or its 

volumetric equivalent.

cup (or cupping)—A form of board warp in which there is a deviation from a 

straight line across the width (McMillen and Wengert 1978).

equilibrium moisture content (EMC)—The moisture content at which wood 

neither gains nor loses moisture when surrounded by air at a given relative humidity and temperature. It is frequently used to indicate potential of an atmosphere to 

bring wood to a specific moisture content during a drying operation (McMillen and 

Wengert 1978).

finger joint—An end joint made up of several meshing wedges or fingers of wood 

bonded together with an adhesive. Fingers are sloped and may be cut parallel to 

either the wide or narrow face of the piece (USDA FS 1999). 

flat-sawn lumber—Lumber that has been sawn parallel to the pith and approximately tangent to the growth rings. Lumber is considered flat grained when the 

annual growth rings make an angle of less than 45° with the surface of the piece 

(USDA FS 1999).

lumber dry kiln—A chamber having controlled air flow, temperature, and relative 

humidity for drying lumber. The temperature is increased as drying progresses, and 

the relative humidity is decreased (USDA FS 1999).

planer—A piece of sawmill equipment that planes rough lumber, leaving it smooth 

and uniform in size. 

quarter-sawn lumber (or edge-grained lumber)—Lumber that has been sawed 

so that the wide surfaces extend approximately at right angles to the annual growth 

rings. Lumber is considered edge grained when the rings form an angle of 45° to 

90° with the wide surface of the piece (USDA FS 1999). 

rip—To cut lengthwise, parallel to the grain (USDA FS 1999).

stain—A discoloration in wood that may be caused by such diverse agencies as 

micro-organisms, metal, or chemicals. The term also applies to materials used to 

impart color to wood (USDA FS 1999). 
22

GENERAL TECHNICAL REPORT PNW-GTR-820 

Metric Equivalents

When you know: Multiply by: To find:

Inches (in) 2.54 Centimeters

Feet (ft) .3048 Meters

Cubic feet (ft3

) .0283 Cubic meters

Pounds per square inch (psi) 6.8947 Kilopascals

Acres .405 Hectares

Board feet, lumber scale .0024 Cubic meters, lumber

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