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SILVA FENNICA
Silva Fennica vol. 47 no. 2 article id 930
Category: research article
www.silvafennica.
ISSN-L 0037-5330 | ISSN 2242-4075 (Online)
The Finnish Society of Forest Science
The Finnish Forest Research Institute
Raffaele Spinelli1, Eugenio Cavallo1, Lars Eliasson2 and Alessio Facello1
Comparing the efciency of drum and disc chippers
Spinelli R., Cavallo E., Eliasson L., Facello A. (2013). Comparing the efciency of drum and
disc chippers. Silva Fennica vol. 2013 no. 2 article id 930. 11 p.
Abstract
The study compared the effect of chipper type on productivity, power demand, fuel consumption
and product quality. Tests were conducted on two commercial chipper models, a disc and a drum
chipper. Both chippers had the same diameter capacity, were applied to the same tractor and fed
with the same feedstock types. Fifteen replications were conducted per machine and for each of
four different feedstock types, reaching a total of 120 tests. The disc chipper had a higher energy
efciency and used 19% less fuel per unit product, possibly due to its simpler design, integrating
comminuting and discharge system in one synergic device. In contrast, the drum chipper was 8%
more productive, since it cut with the same energy all along the length of its knives. The drum
chipper produced smaller chips, with a higher incidence of nes. Feedstock type had a strong
effect on productivity, energy efciency and product quality. The effect of feedstock type was
mainly related to piece size, and may be stronger than the effect of chipper type. Further studies
should determine the effect of blade wear on the relative performance of the two chipper types.
Keywords biomass; energy; productivity; fuel; wood
Addresses 1 CNR IVALSA, Via Madonna del Piano 10, Sesto Fiorentino (FI), Italy; 2 Skogforsk,
Uppsala Science Park, SE-751 83 Uppsala, Sweden E-mail spinelli@ivalsa.cnr.it
Received 28 November 2012 Revised 8 April 2013 Accepted 11 April 2013
Available at http://www.silvafennica./article/930
1 Introduction
Comminution is an essential element of all modern energy wood chains, because automated boilers
need homogeneous fuel particles within specied size limits (Strehler 2000). Besides, comminution
offers additional benets in terms of increased load density and improved handling quality (Röser
et al. 2012). For this reason, low-density raw materials should be chipped as early as possible, in
order to accrue such important benets all along the supply chain (Björheden 2008).
Sound knowledge of technology alternatives is a main step to optimal deployment, which
is made the more urgent by the ambitious European Union targets for the year 2020 (Stupak et al.
2007). These targets require mobilizing the large unutilized wood resource already available in
the territories of member states (Ericsson and Nilsson 2006). In turn, massive mobilization can
only be achieved if the cost of harvesting, processing and transportation is dramatically reduced
(Moiseyev et al. 2011). All steps in the supply chain must be optimized, including chipping, which
accounts for a large share of the overall supply cost (Papworth and Erickson 1966). Such an effort
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Silva Fennica vol. 47 no. 2 article id 930 · Spinelli et al. · Comparing the efciency of drum and disc chippers
requires determining if one chipper design is inherently more efcient than the other, in terms of
productivity and energy use or if it produces a higher product quality.
Based on comminution principle, commercial chippers come in three main types: disc chip-
pers, drum chippers and cone-screw chippers (Pottie and Guimier 1985). The rst two types are by
far the most used, whereas cone-screw-chippers are seldom used professionally when producing
energy chips and are the object of further development (Wegener and Wegener 2012).
Mobile disc chippers are especially common in North America for production of pulp chips,
whereas drum chippers nd a secondary use for brush disposal, often in gardening operations
(Goldstein and Diaz 2005). In Europe, disc chippers or large drum chippers are used on terminals
for chipping of logs, while the drum chippers dominate the chipping of logging residues and small
trees on landings (Kärhä 2011).
Both chipper types have been in use for many years and much anecdotal evidence is avail-
able about their relative merits. Operators state that disc chippers produce more uniform chips
than drum chippers, especially if fed with good quality raw material. In contrast, exible small
branches may pass through the disc slots uncomminuted, resulting in low chip quality. For this
reason, operators believe that drum chippers are the best when dealing with small-size feedstock,
such as tops and branches (Spinelli and Hartsough 2001). Few scientic comparisons of the two
chipper types have been made, rarely with comparable settings for the machines (cf. Young and
Hatton 1976; Heikka and Piirainen 1981; Liss 1984; Liss 1987).
The goal of this study is to compare the specic effect of chipper type (disc or drum) on
productivity, power demand, fuel consumption and product quality, using different raw material
types and running both machine types under comparable (controlled) conditions.
2 Materials and methods
Two mobile chippers were made available by Pezzolato SpA (www.pezzolato.it) and were used
for the experiment: a Pezzolato PTH 300 G drum chipper (Fig. 1) and a Pezzolato H880/250 disc
chipper (Fig. 2). The chippers had the same log diameter capacity and were set to produce the
same cut length, with a blade offset equal to 15 mm and 13 mm for the drum and the disc chipper
respectively. Both chippers used a two-blade conguration. The drum chipper was equipped with
a 50 mm square mesh sieve and the disc chipper with a three-blade piece breaker, in order to limit
the production of oversize particles to the same 50 mm maximum length (Table 1). Both chippers
were new from the factory, eliminating machine wear as a factor in the study. Both chippers were
alternately connected to the same 100 kW farm tractor, a new Case New Holland 140. The rota-
tion regime of the tractor power take off (PTO) was set to the specications recommended by the
chipper manufacturer for each chipper model: 750 rpm for the drum chipper and 540 rpm for the
disc chipper.
The tests were conducted in March 2012 at the wood yard of the Mombracco chip-red
power station in Envie, Northwestern Italy. Both machines were alternately fed with four differ-
ent feedstock types: poplar sawmill residues, poplar branches, poplar logs and chestnut logs. All
feedstocks were fresh and came in pieces with an approximate length of 2 m. The average moisture
content of chestnut logs was 44%, and that of the poplar assortments was between 50 and 52%.
The feedstocks were chosen because they are widely available and often used for chip production
in the area.
The study included 15 repetitions per combination of chipper type and feedstock, totalling
120 repetitions (2 chippers x 4 feedstock types x 15 repetitions). Feedstocks were manually fed to
each chipper in a random sequence in order to dampen the inuence on results from progressive
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Silva Fennica vol. 47 no. 2 article id 930 · Spinelli et al. · Comparing the efciency of drum and disc chippers
blade wear (Nati et al. 2010). Tests were started with new blades on both machines. Each repetition
consisted of around 100 kg of material. The amount of material used was kept intentionally small,
in order to contain the effect of blade wear and to guarantee that the machine was under continu-
ous load for the whole duration of the replicate. It is difcult to feed large amounts of material to
the chipper in a uniform way, and uneven feeding is likely to generate “jagged” load graphs, with
peaks and lows, which are more difcult to analyze.
Fig. 1. The experimental set up with the PTH 300 G drum chipper.
Fig. 2. The experimental set up with the H 880/250 disc chipper.
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Silva Fennica vol. 47 no. 2 article id 930 · Spinelli et al. · Comparing the efciency of drum and disc chippers
Torque was measured with a strain-gauge based torque meter giving a rated voltage output
of 2 mV∙V–1 @ 2250 Nm. Torque measurement accuracy was 0.7 Nm. Rotational speed was deter-
mined with a 60 tooth gear coupled with a magnetic speed sensor giving a pulse output directly
proportional to the speed, accurate to 1 Hz∙rpm–1 @ 5000 rpm). This information was used for
calculating power output.
Fuel consumption was measured with a volumetric fuel meter directly connected to the
engine feed lines (send and return line). The fuel meter had two PT100 thermocouples connected
respectively to the send and return lines for determining the uid temperature and calculating the
appropriate fuel density. Fuel meter accuracy was 0.04 L h–1.
All sensors were connected to a pc-based multichannel acquisition system that ltered, pro-
cessed, displayed and recorded all incoming signals. The instrument could acquire up to 8 analogue
channels and up to 24 digital channels, with a maximum sample rate of 10 ks∙s–1. For this study
the recording sampling rate was xed to 45 samples per second, using 3 analogue (torque meter
bridge and thermocouples) and 2 digital channels (speed sensor and fuel meter).The acquisition
software was congured for real-time processing of acquired data. Therefore, one could immedi-
ately observe such parameters as instantaneous power (kW) and fuel (L∙h–1) use.
Effective time consumption was determined on the power and fuel consumption graphs,
rather than by timing the actual work (Spinelli et al. 2011b). When a machine is processing small
batches, it is difcult for an external observer to accurately determine when the machine is working
and when it is running idle. In fact, the machine evacuation system will keep spitting small amounts
of chips for many seconds after the drum has nished its job. During this time the engine work
load is dropping again. Under real work conditions, a new load would be engaging the drum at this
stage, and the engine work load would not be decreasing so sharply. To determine the beginning
and the end of process time, all graphs were analyzed in order to estimate a basal power and fuel
consumption gure, taken as a reference for the running machine before its drum actually engaged
the wood. These reference gures were adopted as the thresholds for dening actual chipping
time. All test time when fuel consumption or power output was above these levels was counted as
chipping time and used for calculating net chipping productivity. Average fuel consumption when
chipping was also calculated on the records above the idling threshold.
Output was determined by weighing all wood chips produced within each repetition. To this
end, a metal bin was held with a forklift under the chipper spout, in order to collect the chips. The
bin was connected to the forklift with a strap and a hook. The hook contained a 10 kN load cell,
with a rated accuracy of 200 g. The load cell downloaded all weight data into the main pc-based
multichannel acquisition system.
A single one-kg sample was collected from each repetition for determining moisture content
and particle size distribution. The former was obtained with the gravimetric method, according to
Table 1. Characteristics of the test chippers.
Type Drum Disc
Make Pezzolato Pezzolato
Model PTH 300 G H880/250
Year 2012 2012
Serial # CI 5240 CI 5389
Weight kg 2320 1460
Knives n° 2 2
Blade offset mm 15 13
Screen mm 50 NA
Piece breaker NA 3 blades, 40 mm
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Silva Fennica vol. 47 no. 2 article id 930 · Spinelli et al. · Comparing the efciency of drum and disc chippers
European standard CEN/TS 14774-2; the latter with the oscillating screen method, according to
European Standard CEN/TS 15149-1. Eight sieves were used to separate the nine following chip
length classes: >300 mm, 300–200 mm, 200–125 mm, 125–100 mm, 100–63 mm, 63–45 mm,
45–16 mm, 16–3 mm, <3 mm. Each fraction was then weighed with a precision scale.
Data were analyzed with the SAS statistics software using analysis of variance (Anova).
Analysis of variance for particle size distribution was conducted after arcsine transformation, in
order to satisfy the normality assumption.
3 Results
Productivity was 8.3 % higher for the drum chipper than for the disc chipper (Table 2) but the
difference was not signicant at the 5% level (p = 0.0535, Table 3). Productivity was strongly and
signicantly affected by feedstock type, with logs proving faster to chip than branches or saw mill
residues.
When the machines were idling, the average power consumption was 4.6 kW for the disc
and 4.9 kW for the drum chipper. Under these conditions, fuel consumption was 6.3 and 8.4 L per
hour for the disc and the drum chipper combination, respectively.
When working, the drum chipper needed more power than the disc chipper, and more power
was needed when chipping logs compared to branches or saw mill residues (Table 4). Power
requirement was dependent on the amount of material chipped per time unit, i.e. the production
in oven-dry tonne per minute (Table 5). The inclusion of productivity as a covariate in the model
increased the r2 from 67 to 84 per cent, compared to the anova without covariate.
Table 2. Average time consumption (minutes) per
oven-dry tonne chips by chipper and feedstock
type.
Feedstock type Disc Drum ∆ Disc (%)
Chestnut stem 6.28a 5.46a 15.0
Poplar branches 10.17b 8.99b 13.1
Poplar logs 6.73a 6.24a 7.9
Poplar mill residue 9.46b 9.46b 0.0
Note: different letters on the average values in the same column
indicate statistical signicance at the 5 % level; ∆ Disc (%) is the
percent increment recorded for the disc chipper, assuming the
drum chipper value as the reference base, i.e. ; ∆ Disc (%) = 100
* (Disc – Drum)/Drum.
Table 3. Anova table for time consumption per
oven-dry tonne by chipper and feedstock type.
Source DF Type III SS p
Chipper 1 118441.383 0.0535
Feedstock 33447703.362 <0.0001
Chipper*Feedstock 356431.216 0.6132
Table 4. Average power consumption (kW) when
chipping by chipper and feedstock type.
Feedstock type Disc Drum ∆ Disc (%)
Chestnut stem 35.39a 46.26a –23.5
Poplar branches 21.66b 28.83b –24.9
Poplar logs 37.89a 45.99a –17.6
Poplar mill residue 27.92c 34.51c –19.1
Note: different letters on the average values in the same column
indicate statistical signicance at the 5 % level; ∆ Disc (%) is the
percent increment recorded for the disc chipper, assuming the
drum chipper value as the reference base, i.e. ; ∆ Disc (%) = 100
* (Disc – Drum)/Drum.
Table 5. Ancova table for average power consump-
tion when chipping by chipper and feedstock
type with productivity as covariate.
Source DF Type III SS p
Chipper 1 1239.876 <0.0001
Feedstock 31117.873 <0.0001
Chipper*Feedstock 349.275 0.2561
Productivity 12423.577 <0.0001
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Table 6. Consumed energy (MJ) per oven-dry tonne
chips by chipper and feedstock type.
Feedstock type Disc Drum ∆ Disc (%)
Chestnut stem 20.80a 24.81a –16.2
Poplar branches 21.38a 25.34a –15.6
Poplar logs 24.95b 28.40b –12.1
Poplar mill residue 26.12b 32.15b –18.8
Note: different letters on the average values in the same column
indicate statistical signicance at the 5 % level; ∆ Disc (%) is
the percent increment recorded for the disc chipper, assuming the
drum chipper value as the reference base, i.e. ; ∆ Disc (%) = 100
* (Disc – Drum)/Drum.
Table 7. Anova table for consumed energy per
oven-dry tonne by chipper and feedstock type.
Source DF Type III SS p
Chipper 1 575710069.9 <0.0001
Feedstock 3800329555.6 <0.0001
Chipper*Feedstock 329352520.4 0.5779
Table 8. Consumed diesel fuel (L) per oven-dry
tonne chips by chipper and feedstock type.
Feedstock type Disc Drum ∆ Disc (%)
Chestnut stem 2.36a 2.73a –13.6
Poplar branches 2.92b 3.35b –12.8
Poplar logs 2.67b 3.21b –16.8
Poplar mill residue 3.11c 3.94c –21.1
Note: different letters on the average values in the same column
indicate statistical signicance at the 5 % level; ∆ Disc (%) is
the percent increment recorded for the disc chipper, assuming the
drum chipper value as the reference base, i.e. ; ∆ Disc (%) = 100
* (Disc – Drum)/Drum.
Table 9. Anova table for consumed diesel fuel per
oven-dry tonne by chipper and feedstock type.
Source DF Type III SS p
Chipper 1 8.957 <0.0001
Feedstock 315.375 <0.0001
Chipper*Feedstock 30.924 0.3818
Fig. 3. Average chip size distribution for the disc chipper (grey bars) and drum chipper
(black bars).
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Silva Fennica vol. 47 no. 2 article id 930 · Spinelli et al. · Comparing the efciency of drum and disc chippers
The higher average power demand of the drum chipper made it less energy efcient than
the disc chipper. As an average, the drum chipper used 18% more energy per oven-dry tonne,
compared to the disc chipper (Table 6). This difference was statistically signicant, as were the
differences caused by feedstock type (Table 7). The lower energy efciency of the drum chip-
per was also reected in the 19% higher fuel consumption per oven-dry tonne (Tables 8 and 9).
Chestnut logs proved to be the most energy efcient feedstock to chip, and mill residues the least
efcient, regardless of how energy consumption was measured: MJ per oven-dry tonne, or L of
diesel per oven-dry tonne. The effect of feedstock type was stronger than the effect of chipper type
in determining energy use (Tables 7 and 9).
On average, the disc chipper produced signicantly more acceptable size chips (8–16 mm)
and signicantly less small chips (8–3 mm) and nes (<3 mm) than the drum chipper (Fig. 3).
There were also clear differences between feedstock types. Chestnut logs and poplar branches pro-
duced a lower amount of 8–16 mm chips and more nes (<3) than poplar logs or sawmill residues
(Table 10). However, for the two nest particle size fractions there was a signicant interaction
between the chipper and feedstock type (Table 11). The disc chipper produced the least amount of
these fractions when chipping sawmill residues, while the drum chipper obtained the same effect
with poplar logs. Logically, this led to a proportional difference in the amount of 8–16 mm chips,
but such difference was not large enough to cause a signicant interaction effect. However, when
fed with sawmill residues, the disc chipper produced a far better product than what the general
comparison between the two chipper types suggests.
Table 10. Particle size distribution by chipper and feedstock
type.
Chipper Disc Drum
Chestnut logs
>45 mm 0.1 0.1
45–16 mm 3.8 3.4
15.9–8 mm 50.9 43.7
7.9–3 mm 36.4 42.6
<3 mm 8.8 10.2
Poplar logs
>45 mm 0.0 0.1
45–16 mm 3.8 3.5
15.9–8 mm 63.7 60.5
7.9–3 mm 25.7 27.0
<3 mm 6.8 8.9
Poplar branches
>45 mm 0.3 0.4
45–16 mm 5.5 5.5
15.9–8 mm 52.7 44.9
7.9–3 mm 32.0 36.5
<3 mm 9.5 12.7
Sawmill residues
>45 mm 0.5 0.4
45–16 mm 9.6 7.8
15.9–8 mm 62.9 50.5
7.9–3 mm 21.5 31.1
<3 mm 5.6 10.2
Note: data obtained from back-transformation of Arcsine transformed data.
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Silva Fennica vol. 47 no. 2 article id 930 · Spinelli et al. · Comparing the efciency of drum and disc chippers
4 Discussion
The amount of wood processed during the experiment was relatively small (7.1 oven-dry tonnes),
and much smaller than used for more conventional studies, where a trailer load is often taken as
the observation unit (Spinelli and Magagnotti 2013). However, this study was conducted on single
batches with the specic goals of: 1) containing the effect of blade wear and 2) making sure that the
machine was under continuous load for the whole duration of the test. Furthermore, the individual
size of each replicate was representative of the single load that is fed manually or with a small
grapple to machines that are designed for being fed that way. All measures were taken to guarantee
that the small replicate size would not bias the reliability of our results. In particular, calculating
process time from power and fuel use graphs allowed preventing the risk of manual timing errors
Analysis of data did not detect any signicant drift within the same machine treatment,
showing that the use of small batches succeeded in containing the effect of blade wear.
The effect of feedstock type on productivity is well known, and has been reported in previous
studies (Liss 1987; Spinelli et al. 2011). The largest part of the difference can be ascribed to the
effect of piece size on chipper productivity (Spinelli and Magagnotti 2010). That would explain why
the highest productivity in the study was achieved for logs, and the lowest for branches and slabs.
The higher productivity recorded for the drum chipper was not signicant at the 5% level,
although the margin of uncertainty was very little. So, we cannot ignore the possibility that the
drum chipper could be more productive than the disc chipper. That would be in accordance with
earlier studies (Liss 1984; Heikka and Piirainen 1981) and may be an effect of the larger effective
work width. While both test machines had the same infeed opening and were rated for the same
diameter capacity, the working face of the drum chipper ran at a constant peripheral speed. On the
contrary, the peripheral speed of the disc chipper varied with the distance from the disc centre,
and therefore the disc chipper was less effective due to lower speed and momentum in the por-
Table 11. Anova table for particle size distribution.
Source DF Type III SS p
>45 mm
Chipper 1 6.502 * 10–5 0.8889
Feedstock 30.043 0.0063
Chipper*Feedstock 3 0.001 0.9505
45–16 mm
Chipper 1 0.005 0.1926
Feedstock 30.237 <0.0001
Chipper*Feedstock 30.004 0.6782
15.9–8 mm
Chipper 1 0.179 <0.0001
Feedstock 30.455 <0.0001
Chipper*Feedstock 3 0.031 0.1114
7.9–3 mm
Chipper 1 859.638 <0.0001
Feedstock 33730.834 <0.0001
Chipper*Feedstock 3263.547 0.0529
<3 mm
Chipper 1 0.074 <0.0001
Feedstock 30.065 <0.0001
Chipper*Feedstock 30.016 0.0458
Note: analysis conducted after arcsine transformation.
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Silva Fennica vol. 47 no. 2 article id 930 · Spinelli et al. · Comparing the efciency of drum and disc chippers
tion of the blade that was nearer to the centre. That is an inherent quality of disc chippers, and a
conceptual difference to drum chippers.
The differences in power requirement when idling for the two chipper types are likely
explained by a higher resistance of the evacuation system installed on Central European drum
chippers, which in this case consists of two auger conveyors and a blower. That is made necessary
by the interposition of a resizing screen between the drum and the chip outlet, which inevitably
chokes the free ow of chips. Therefore, chips must be collected and moved to a separate blower for
launching through the discharge spout. Disc chippers have no such screens, and the initial accelera-
tion impressed to the chips by the integral fan blades on the outlet facing side of the disc is enough
for thrusting the chips through the discharge spout, without any need for additional conveyors or
blowers. The main advantage of the disc chipper design is that the two devices – comminuter and
blower – are integrated into one single mechanism developing a synergic action.
In a similar study of a tractor powered Bruks 722 disc chipper Liss (1987) reported a power
consumption when idling of 3.2 to 3.5 kW, which is quite close to the 4.6 kW indicated in this
study. Liss also reported a mean power requirement of 18.2 kW when chipping spruce logs of 100
mm diameter with a 50 % moisture content at a temperature of –10 °C. Power requirement rose
to 36.2 kW when log diameter increased to 150 mm.
Logically, logs require more power to chip compared to branches or slabs as the pieces are
larger. However, the higher productivity achieved through the large piece size resulted in a better
energy efciency. This was highest with chestnut logs and lowest with poplar slabs, possibly due
to the combined effect of piece size and wood characteristics, with special reference to moisture
content. In fact, efciency was calculated on the basis of dry matter, which likely favoured the
drier chestnut logs. Specic fuel consumption seemed closely related to productivity, being higher
for slabs and branches compared to logs.
The study did not verify that disc chippers produce more oversize particles compared to
drum chippers, which is reported by many practitioners. However, the experiment was conducted
on large hardwood branches with no foliage, after winter harvesting. Different results may have
been obtained if chipping very small branches, with foliage and twigs. Furthermore, the test was
conducted with new blades and with a rather small disc chipper, which may also explain partly
unexpected results. The production of oversize particles increases with blade wear (Nati et al.
2010), and in that case the presence of a resizing screen could represent a crucial advantage offered
by drum chippers. The small infeed opening makes it less likely that material will bend and reach
the disc in parallel to the chipping knife. On a large disc chipper this may occur especially when
fresh small diameter undelimbed material (i.e. tops or tree sections from thinnings) is chipped.
Operators report that the piece breakers installed on disc chippers are not as effective as a proper
resizing screen. Therefore, it could be useful to repeat the experiment with worn blades and thin-
ner branch material. The signicantly higher proportion of small chips and nes produced by the
drum chipper is likely caused by the resizing screen and the more complex evacuation system,
whose augers and blower “churn” and “beat” the chips.
Finally, readers should be aware that the study was conducted on two specic small-size
chipper models. Although generally representative of machines in their class, the two chippers used
for this study could not reect all design options available for small size disc and drum chippers.
Therefore, one should be very careful when generalizing the results of this study, especially when
generalization is applied to large-size industrial chippers.
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Silva Fennica vol. 47 no. 2 article id 930 · Spinelli et al. · Comparing the efciency of drum and disc chippers
5 Conclusions
Due to their simpler design, disc chippers are more energy efcient than drum chippers, but the
latter are possibly more productive. Both chipper types offer good product quality, at least as long
as their blades are sharp. Drum chippers tend to produce smaller chips, with a higher incidence
of nes. Further studies should determine the effect of blade wear on the relative performance of
the two chipper types. Feedstock type has a strong effect on productivity, energy efciency and
product quality. The effect of feedstock type is mainly related to piece size, and may be stronger
than the effect of chipper type.
Acknowledgements
This study was funded in part by the Regione Piemonte, through the project DCU NET. The
Authors gratefully acknowledge the technical support of Pezzolato SpA, who offered the chipper
and their personnel for the test.
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