• 1. Optional: Lumber Dumper
  • 2. Inclined Belt Conveyor
  • 3. Smart 3D Laser Scanner
  • 4. Dual End Cut Saw Deck
  • 5. Drop Sorter
  • 6. 6 Category Compact Bins

Optional: Lumber Dumper


Inclined Belt Conveyor


Smart 3D Laser Scanner


Dual End Cut Saw Deck


Drop Sorter


6 Category Compact Bins

Customization based on your needs.​

Increase the feed speed with The Robotic Pallet Dismantler
Combine with our Sort & Repair Systems

Badger Sawmill Series

The increased adoption of the Robotic Pallet Dismantler, by all sizes of facilities in the pallet industry, has given rise to the Badger Sawmill Series. The Badger Sawmill Series will scan every piece of lumber through our vision system to determine length, width and thickness to trim the lumber to the preset dimensions. This process will maximize every piece of lumber. You get the key functions of scanning, optimizing, trimming, and sorting in a smaller footprint that will increase your yield gain by 10%.

DYNAMIC DUO Robotic Pallet Dismantler feeding the Badger Sawmill Series

When working together, this dynamic duo will increase efficiency, yield, throughput and safety.


Take a closer look at the benefits your company will gain with the Badger Sawmill Series. Follow the link to download the brochure for specifications.



The Badger Sawmill Series comes standard
with the following capabilities:

Infeed: 22’ 2”
  • 20’ inclined, 48” wide infeed belt conveyor with lumber presentation device
Saw deck: 25’ ¾”
  • Line speed of 15,000 board per 7.5 hour shift
  • Single cut saw deck capable of cutting boards
    • Width: 1.5″ to 6″
    • Thickness: 3/8″ to 2″
    • Length: 28″ to 52″
    • Fence travel 4″ per side with a total of 8″ trim.
Outfeed: 10’
  • 10’ Long 36” wide outfeed conveyor
Standard Badger Sawmill Series length:
  • 57’ 2¾”
Badger Sawmill Series Rendering

Build Your Own Badger By Filling Out This Form

The Badger Sawmill Series comes with standardization but here you can customize your Badger to fit the needs of your business.

Line Speed Upgrade Option:
(Based on a 7.5 hour working shift)
Infeed Options:
Saw Deck Options:
(Select all that are required)
Outfeed Options:
(Select all that are required) *Additional bulk bins must be ordered in even numbers. A standard bulk bin holds 700 boards and is 40” wide. A compact bulk bin holds 350 boards and is 24” wide.
Outfeed Options:

Are you in need of additional parts for your Badger Sawmill Series? Take a look at the spare parts package we have to offer by downloading the file below.

Badger Sawmill Series FAQ

  • Scanning technology uses the same 3D line scan hardware and software.
  • The PLC (programmable logic controllers) and HMI (human-machine interface) programming are adapted from the Urban Sawmill.
  • The Infeed conveyor is the same heavy-duty construction.
  • Saw motors, saw blades, fence servo actuators, duck bills, and duck bill cylinders are all the same.
  • Speed and the maximum boards cut per shift is reduced.
  • Maximum board length drops 10” from 62” down to 52”.
  • Maximum board width is 2” less, from 8” down to 6”.
  • No drop deck or unscrambler on standard sawmill, these are options.
  • Lumber presentation device has been added to the end of the infeed conveyor on the Badger Sawmill.
  • Lumber infeed will be controlled by a foot pedal rather than automatically via sensors.
  • The operator loads directly to the saw deck, thus removal of the staging and lug loader sections.
  • The saw deck chain and drop sorter chain changed from 81X chain to 2080 chain.
  • The saw deck is angled to remove the need for an operator platform.
  • Duck bill cylinder has been improved to a fixed welded arm rather than the QD bushing.
  • Redesigned drop sorter frame to remove unnecessary material (no functional or durability loss).
  • The Badger is identified as a series because of the different speeds available and the optional 20” board cut option. A 150 series sawmill will provide you 15,000 boards per shift, a 200 series will provide you with 20,000 boards per shift. If you opt to add the “S” series to your 150 or 200 you will be able to cut 20” boards.
  1. Lumber fed to the machine on a consistent basis. (Never starved)
  2. Lug fill percentage of 90%+ will allow you to process more boards.
  3. The lumber loader should not be sorting out blocks, broken boards, or other debris.
  4. Running speed of the machine directly impacts the operation and maximizing output.
  5. Attention to the machine, clearing jams, skews, and vision failures quickly.
  6. Operation hours of the machine are also critical to output success and maximization.

Failures in any of these keys will lead to reduced productivity. All the keys are very achievable, but they must be prioritized to achieve maximum production.

  • The Badger Sawmill does not require any more maintenance than any other wood equipment. Greasing bearings and chains on a schedule, cleaning sensors and camera lenses, checking bolt tightness, and general cleaning is all that is required. We provide a full maintenance schedule within the manual.


  • The Control interface to the machine is programmed in both Spanish and English. You just hit a button to toggle between the two languages.
  • The saw deck load operator can work from either side. It is often a best practice for the bin tender and the lug loader to be on the same side so they can communicate, though this is not required.
  • Alliance Automation does not offer dust collection systems. We do provide dust collection ports in the saw covers. It is the end user’s responsibility and liability to add dust collection if they desire.
  • It allows for the trimmed material to be brought to one side of the machine. This is often helpful if the machine is against a wall. Since the conveyors are an inclined rough top belt, it allows for a larger trim hopper to be used thereby lengthening the service interval.


  • Typical blade life between resharpening is 2 shifts if running deck boards only. 1 shift if running stringers only.
  • We recommend a total of 10 blades, therefore the system comes with 10 blades at the time of purchase. If you are only running deck boards, one shift a day, and you have a weekly re-sharp rotation = 5 blades a week in the plant, 5 blades being re-sharpened, and we recommend an additional 5
  • Very easy to change. One bolt to access the guard, one nut holding the blade on. An average technician should be able to change both blades in under 5 minutes.


  • This option changes the design of the entire system. The saw deck will require two additional justification rollers, and an additional chain strand. The drop sort would also requires an additional chain to be added. This feature will also require additional sensing throughout the machine.
  • There are no disadvantage. It simply allows more flexibility in cutting options. It allows you to cut a 52” board down to 32”. The big advantage for most customers is cutting a 52” down to 40”. The standard 8” cut will not allow for this.
  • Yes, it would make the system more affordable, but you lose the opportunity to cut boards and strings at the same time.


  • “failed to fence” there is a sensor to tell the machine if the board to be cut registered on the moving fence. If the board does not make it, this is a “fail to fence”. Reasons for fail to fence: nails sticking down, and extreme bowing are the main reasons
  • “destination not found” This is when the machine simply cannot cut the board to any of the categories set up in the drop sort bins.
  • This greatly varies based on the quality of the inbound product. In general, we expect to see less than 5% rejects
  • Any boards that were rejected for “fail to fence” have a chance to get cut and sorted during the second pass. “destination not found” boards will be rejected again.
  • The three scenarios that will stop the Badger Sawmill are “vision system immediate reject”, which is an incoming board that is either too long or too short, more than one board in a lug, or a “skewed” board, this is when a board will be kicked at the saw and become “skewed” in the chain lugs. All three of the above scenarios take a few seconds to recover from.


  • Infeed belt, drop deck, and unscrambler are all designed with productivity in mind. This infeed combination gives you the most flexibility of how you present lumber to the machine, and provides the lug loader with the most consistent board flow
  • Lug loader pulling right out of a bin is the most cost-effective infeed option. You will give up throughput and it is a less than ideal ergonomic design. The stand-alone infeed belt conveyor is a great, cost-effective method to feed the machine.
  • You do not need a drop deck with an unscrambler, without a drop deck, you will need to be more diligent about making sure the product on the infeed belt is free of blocks, broken boards, etc. The main function of the drop deck is to allow “trash” to fall through and prevent unscrambler jamming due to trash.
  • The ability to load a full bin of lumber and drive away. The tipping and metering out is controlled by the lug loader.


  • This depends on the speed you are running, the lug fill percentage, and what percentage of boards are going into a specific bin. On average, 3/8” thick – 4” wide boards: full-size average: 700 boards; compact average: 350 boards
  • You can put a full-size bin under two compact drop categories. You would just need to assign both categories to the same board.
  • You can load and unload bins from either side of the machine. Note: all the boards in the drop sort area are justified to the left side of the machine (left side as you are traveling down the machine as a board would) Keep this is mind, as it is easier to straighten boards out in a bin on the left side of the sort deck.
  • The bin system is modular in design. Each module has two sort categories for both the Standard and Compact drop sorters.
  • The bin setup can be accomplished at the machine or from a remote computer.


  • Installation takes roughly two weeks. One week to setup the Badger in your facility with your chosen options. The second week is operating the machine and training. The expectation is by noon of the second week you are running full production with assistance from the Alliance training professional. There are a handful of items the customer must be ready with and accomplish in a timely manner for a smooth installation.
  • Increase throughput of cut lumber
  • Process boards and stringers at the same time
  • Ensure lumber is cut to maximize every piece
  • Eliminate the need for multiple manual saws
  • Ensure a safer work environment
  • Concept designed to fit your facility
  • Install and training included
  • Post install support
  • Daily production report available
  • Remote service access
  • One year warranty
  • Assigned service team
  • Multiple infeed options
  • Bulk vs. hand unload
  • Custom configuration of sort categories
  • Peripheral equipment integration
  • Sawdust/scrap conveyance
  • Multi-year service plan

You Can't Afford Not to Adopt Automation

Think automation is too expensive for your business? Think again.

With the help of our current automation users, we have developed a payback calculator to show how affordable adopting automation is. Click the link below and enter in your company’s data to see just how cost-effective automation can be for you.

Interested in learning more about what Alliance Automation can do for you?