A conversation between Grant Stewart and a forestry management company sparked a rethink on how to handle skyline control with less strain and more precision. Grant鈥檚 initial hesitation about using a grapple carriage opened the door to exploring new ideas, eventually leading to a practical, custom-built solution that is now making a real difference in day to day operations.
It began with a simple chat between Grant Stewart of Stewart Logging and a forestry management company, a conversation that turned into a win-win for both parties.
Grant had been hesitant about adding a grapple carriage to his operation after hearing of other contractors鈥� struggles. 鈥淚鈥檇 heard stories where operators were raising and lowering the skyline every cycle,鈥� he recalls. 鈥淭hat kind of setup can potentially double the wear and half the lifespan of the skyline so we had to be careful with introducing one into our operation. It鈥檚 also hard on the brakes and clutches of the yarder.鈥�
The issue, as Grant points out, is that some tower yarders weren鈥檛 originally designed to raise and lower the skyline every cycle, a process that can be punishing on the ropes in certain settings. Initially, he considered the Falcon Tandem Carriage, but soon his attention turned to finding an alternative solution better suited to his crew鈥檚 terrain and working style.
Grant credits much of the inspiration to other local contractors Matt and Bill Winmill of Gillian Logging, who faced similar challenges. 鈥淢att and Bill came up with a clever solution that really caught my eye,鈥� Grant says. 鈥淭hey designed it themselves, and I thought, why not see if we can incorporate something like that into our own operation?鈥�
That idea kicked off a collaboration between Stewart Logging and the Falcon Innovation Team, resulting in a custom Falcon Winch Assist built specifically to improve skyline control while maintaining the durability of the system.
At the heart of the project was a goal: give the hauler operator direct, precise control of the skyline without relying on the tower鈥檚 braking system.
The DC 爱豆传媒t design team worked closely with Stewart Logging to adapt the Falcon Winch Assist. The result: a custom machine allowing the winch to connect seamlessly with the hauler controls. The operator can now raise or lower the skyline hydraulically, smoothly, safely, and without the mechanical strain of conventional braking of the 172.
Grant and his team went one step further, adding a strawline drum. This small addition has made a big difference, significantly cutting down setup time and giving the crew more agility on site. 鈥淚t鈥檚 a minimal extra cost, but it saves a heap of time,鈥� Grant says. 鈥淲e only need to walk the strawline once from the tail hold to the hauler, after that it鈥檚 all ready to go.鈥�
Grant鈥檚 son, Matt Stewart, who operates the Madill 172 tower yarder, says the system has been transformative.
鈥淗e loves being able to control the tension through the eight winch settings,鈥� Grant notes. 鈥淚t鈥檚 given us access to wood in places we would鈥檝e struggled to reach before.鈥�
In typical setups, the crew runs the Falcon Winch Assist at the top of the hill, routing it through a block or a backline machine to handle the steep slopes. Previously, this required manual hookups and breaker outs, but now, with a second Falcon Winch Assist, much of that physical work has been eliminated. 鈥淭he stems are placed directly where the Falcon Claw can grab them,鈥� Grant explains. 鈥淚t鈥檚 made a huge difference in safety and efficiency.鈥�
One of the biggest advantages is versatility. When the Madill 172 isn鈥檛 pulling wood, the custom Falcon Winch Assist can be repurposed for ground based or skidder operations.
鈥淭hat鈥檚 the beauty of it,鈥� says Grant. 鈥淚f the hauler鈥檚 idle, the Winch Assist can still earn its keep. We can reallocate it to support our falling or ground operations. It keeps uptime and productivity high.鈥�
For Stewart Logging, the project represents more than a mechanical upgrade, it鈥檚 a story of innovation born in the bush.
鈥淚t鈥檚 a good feeling seeing something you鈥檝e talked about turn into reality,鈥� Grant reflects. 鈥淎nd to see it working every day, doing what we hoped it would, that鈥檚 the best part.鈥�
The collaboration is a clear example of Falcon鈥檚 innovation philosophy: smart ideas driven by real world experience.
鈥淥perators like Grant and Matt are the reason Falcon machines keep evolving,鈥� says DC 爱豆传媒t Spokesperson Tom Filmer. 鈥淭hey鈥檙e the ones who see what鈥檚 possible, we just help make it happen.鈥�