March 16th, 2009 fmorgan
One of the many big surprises to me when we moved down to Costa Rica was how primitive the wood business was. Here you have a country with hardware stores, tools, etc. but if you want wood, you go to the sawmill and buy green! There are also depositos de madera, or lumberyards, but they usually sell green wood, too. Of course, you can’t install it green, so you have to dry it yourself.
Many people who are building their own home in Costa Rica are surprised to find that you can’t just go down to something like Home Depot and buy a 2×4; nope, you have to find it. Then, after you find it, make sure to get more than you need, because some of them are going to warp, especially if you don’t know how to dry it properly.
The Ticos are an interesting mix of planning and not planning. If they are building your home, it is hard to find someone who understands buying supplies ahead. I think I have finally figured out why. Most Ticos accumulate material and build in stages. Unlike we do in the USA, they don’t generally get a loan, but they store up money for labor and materials until they have enough to start. This means the wood they need for beams, etc. has probably been in the barn for a few years.
We, on the other hand, land here and want to build our home now, the sooner the better. Often the wood is not available except in a tree somewhere, which will require permits that take weeks to get. The wood will be rough cut, often by a chainsaw, then you will wait perhaps 3 months or more for it to dry (sort of). Since most construction people have nothing more than a power hand planer, the cost of planing and sanding can cost as much as the wood itself.
We paid our dues on this for sure. The first house we built was from trees to house using chainsaws with guides and a 15″ planer. It felt like the timeline for the construction was stretching out forever (we know those of you who live here can relate).
As we grew, so did our milling operation, and we got faster and faster — and more predictable. Now if we need a beam, it comes out of the factory dry, at the right dimensions, planed and sanded and ready to install. The cost of planing and sanding isn’t much when you have the equipment. It is a lot less than paying a construction person to do it by hand. In fact, the costs saved in having the wood ready almost pays for the wood itself when you deduct the labor cost of working with rough cut wood. And of course, the quality is better. We use specialty equipment that allows us to work with beautifully grained wood that would otherwise have a lot of tearouts. With our equipment, we are able to make gorgeous teak products that cost about the same as cedar.
Now we are in the process of educating the construction bosses from Guanacaste to the central valley that they can buy wood ready to install, which helps keep their clients happy. We not only sell the dimensional lumber, but also the tongue-end-groove wood for ceilings and walls (called tablilla here) and floors. In fact, just about anything that is wood in a house, from furniture to cabinets, to floors and doors, we make and sell. And that uses a lot of wood, which is good for our tree owners.
Posted in business in Costa Rica, cabinets, campo, construction, cultural adaptation, doors, drying wood, forestry, furniture, kiln, tablilla, teak, trees, wood | 1 Comment »
September 19th, 2008 fmorgan
Here in Costa Rica, there are about 2,000 different kinds of trees, at least 150 of them are good for lumber. You would think seeds would be easy to get.
Nope, not at all. Generally when we try to order seeds, we find 4 or 5 different types readily available. These would be teak, gmelina, mahogany, cocobolo, and acacia. Everything else is fairly unpredictable.
I personally am not fond of monocrop plantations. They are not very interesting and for native species, not very good. Native trees grow better mixed — like in nature.
The majority of the rare trees we plant are from seeds that we collect within our plantations. This year, the only way we were able to find almendro was from our own trees. All of our cebo was from our own trees as well. A big bonus this year was finding balsamo, a very rare tree with wood as valuable (if not moreso) than cocobolo.
When we first arrived in Costa Rica, I thought to grow trees would be as easy as calling up a tree nursery, ordering the seedlings, and planting them when they arrived. I figured some day we would have a nursery, but just because of volume. The truth is, the only way that we could get the seedlings we needed was to have our own nursery. Nothing else worked reliably.
I am sure it is frustrating for some of our clients that in January they might order, say, 500 cristobal trees and I have to say, “It depends on if there are seeds.” This really emphasizes that what we are doing is working in an area that requires the cooperation of nature, and nature at times will decide that this is not a good year to produce certain seeds.
A good example is our mango trees on our property this year. I was starting to wonder if the mango trees we had actually did produce fruit, because for two years there was none. But this year they more than made up for it and there were mangos everywhere! The same thing is true for seeds we need in the plantations — we can’t just plant whatever we would like, because at times, Mother Nature doesn’t give us any seeds.
Another thing we often do is collect seedlings, or as they are called in the USA, wildlings. Currently in the plantation where we live, there are lots and lots of seedlings that have sprouted in the last month or so. We will go out and carefully extract them from the ground and put into bags, to plant inside the farms. Often, these are the best possible seedlings because they have already shown their vigour in surviving.
Aside from the very popular plantation trees, we never know exactly what we are doing to have to plant, but, that keeps it interesting.
Posted in acacia, campo, cebo, finca, forest, forestry, mahogany, nursery, seedlings, teak, tree owners, trees, wood | No Comments »
July 18th, 2008 fmorgan
After living in Costa Rica for nearly 4 years, I am finding that I am turning bilingual. Not like Amy who can speak English and Spanish very well - I have enough problems with English. This is not to say that I can’t communicate well in Spanish, I do, it is just I mangle it at times.
When I say I am turning bilingual, I mean that there are words that between English and Spanish, I select the one from one language or the other, depending on the concept I am trying to express, even though they both, in theory, mean the same.
A good example is months of the year. July means hot, dusty, Fourth of July - grass dying, daylight until 9 pm, etc. Julio (Spanish for July) means planting seasons, mud, everything super green, well into the rainy season with no sign of dry for the next 6 months. If I say that it is July now, my brain gets seriously confused. Darkness here is at 6 pm and we have roughly 12 hours of daylight. That should be March, but no, it is too warm. Much easier for me to think, it is julio now.
Another word is nursery, as in our tree nursery. My family had nurseries in the USA, and a nursery is something with a plastic over it and a source of heat so you can start plants early while there is still threat of frost. Excuse me? Costa Rica doesn’t even use the word for frost, unless maybe it is referring to what builds up inside the freezer. What we have here is a vivero, where you put up shading material so that the new seedlings aren’t cooked by the sun, even during the rainy season. Also, since we tend to start the seedlings during the dry season, a water supply is important - and there is no need to worry about heat, except perhaps heat stroke!
One last example is when we are talking about measurements of wood. The standard measurement here is a pulgada cubica (cubic inch) which doesn’t mean a square inch like in English. It is 132 square inches. Usually, in the USA we are used to using board foot (BF), which is 144 square inches. The reason is that a pulgada cubica (usually just said pulgada) is 1 inch by 1 inch by 4 varas. What is a vara you say? It is 33 inches. So, 4 x 33 = 132. A curiosity is that they used to use varas for measuring land in Texas. So, I think readily in pulgadas now - which is a good thing because it is how you buy wood here. You can imagine the confusion when people first start dealing with wood here and someone says that it is 1 dollar per cubic inch!
Before we moved to Costa Rica, I was talking to a little girl whose parents were North American and Costa Rican. She had two sets of grandparents, one who was English speaking, the other who spoke Spanish. She was completely bilingual. Once while making conversation in Spanish, I asked her about her abuelos (grandparents) in California. She told me she had no abuelos in California, only grandparents. In her mind, the parents of her tico father were the only abuelos she had, the others where grandparents. At the time I was amazed, but now I am starting to understand.
Posted in Spanish, business in Costa Rica, communications, cultural adaptation, language learning, nursery, trees, wood | No Comments »
July 3rd, 2008 fmorgan
We use motorized brush cutters (weedwhackers) a lot in the farms. Pretty much all day long you hear them running. Here in Costa Rica, they are called motoguadañas, or motorized scythes. They even cut the grass on the lawns with them rather than using lawnmowers, because the lawns are not rolled smooth.
A motoguadaña here costs about 250,000 colones, or in 2008, 500 dollars. When they are used about 7 hours a day, you can expect them to survive about 2 years before they start to become more trouble than they are worth. Generally speaking, you have to clean the motoguadañas once a week (grease, clean, etc.) or they will deteriorate much more rapidly. The consumption of fuel for a day is about one gallon. That doesn’t sound like much, except down here that costs about 6 dollars now. The mixing oil is a bit more. A good operator can cut about 3,000 square meters a day, or a bit less than an acre.
All of this adds up when you have 750 acres or so. We cut the grass on every bit of the land around our trees once every two months for the first two years. After that, it is about every 6 months. The trees grow really fast in our part of Costa Rica, but so does everything else. You have to keep up with it or it will effect the final shape of the tree and their growth.
Before there were motoguadañas, there were guadañas, or scythes. After a lot of research, we decided that scythes might just make a good replacement for the motoguadañas. It is a bit hard to believe, but in the hand of a person who knows what they are doing, a scythe is actually faster and less work than a motoguadaña.
At least, that is the theory.
Yesterday, the scythes arrived. Since it isn’t the easiest thing in the world to get shipments here, I went ahead and ordered 13 of them. Since we can make our own snaths (the handles), I ordered 5 of them in different styles so we would have something to go by. We also got all the stuff to sharpen the blades.
To prepare people for the coming of the new and improved motoguadaña, I showed them a video of a young girl beating an operator of a motoguadaña in a contest. They were impressed, and of course, since it was a little girl (about 11 years old I believe), I am sure they are convinced they can do at least as well as she!
It appears to be true. Yesterday, I showed Ignacio, our gardener, the scythe. After I explained how it worked, he was off and running. He is convinced that with just a little time, it will be faster than a motoguadaña.
One really big advantage is that the women can use the scythes, whereas a motoguadaña (commercial size) is a bit much for the average sized Tica. Many of the women in the area would love to work clearing the grass but could not before. There isn’t a lot of work for the women in the area, so this opens up possibilities. One other benefit that I really didn’t expect is safety. You wouldn’t think a knife that is nearly a meter long would be safer - but motoguadañas throw a lot of debris and those who operate them often don’t consider this. The other safety issue is your hearing. The steady noise of a motoguadaña can’t be good for your long term hearing and it masks the sound of a snake as well.
So far, the scythe experiment is going very well, although there was a pretty startled look on the faces of the people working nearby when I walked out of my office holding a scythe for the first time, looking like the Grim Reaper…
Posted in campo, conservation, cultural adaptation, culture, importing, scythe, trees, wood | No Comments »
June 20th, 2008 fmorgan
Due to our plantations, we are on a first name basis with MINAE, the ministry of environment. This can be an adventure in and of itself. MINAE has the responsibility to safeguard the forest and environment of Costa Rica. Like many government organizations, they are understaffed for the size of the job.
We truly try to follow all the rules of Costa Rica. This can be a real trial at times. Not because of the rules, but because of timetables.
Just to give an example, we recently hauled all of those great logs out of the river from the old bridge. Come to find out, before we could cut them, we had to have MINAE visit to verify - even though we sent them pictures. But we had to wait. We were already waiting for 13+ weeks for other permits! I thought we wouldn’t need permits for the bridge logs until it was time to transport the wood, but nope, before we cut it up too (Strange, the trees have been dead for years and years…).
Finally, MINAE notified us that they were ready to come and would meet us at the gas station in Monterrey. Our forestry engineer, Angie, and one of our wood experts went to meet with them and all went great. Angie asked, “What was the holdup?”
The answer, believe it or not, was that they didn’t have enough money for gas to come out and visit! Angie actually gave them some money for gas so they could return to their office, knowing that we would reimburse her.
I wish I had known so that we could have offered to pay expenses. MINAE has taken us up before on our offer to provide horses for them to inspect our properties, so why should this be any different?
Posted in MINAE, business in Costa Rica, forestry, resources, wood | No Comments »
May 6th, 2008 fmorgan
Due to the overall lack of capital in a developing economy like Costa Rica, the availability of heavy equipment of any type is not very good. To get a backhoe to do some work, you have to commit to no less than 3 days, and often 1 week of work to make it worth their while.
But you don’t always need a week’s worth of work, so a lot of the work is done by hand. This makes for very efficient ditch diggers. We had one worker who was incredible. Give him a shovel and tell him to make a hole and you better get back quickly to tell him to stop or he would be in China!
But, as we have grown, so have our needs. With more than 500 acres of plantions, road and bridge repair is a pretty much yearly cost - and a sizeable one. Also, the nursery needs dirt from somewhere. We have found it quickly uses the topsoil around it - so we have to haul it in.
So, we bought a backhoe. Now, that seems like just a simple thing and it is, but the emotional impact is significant to me. I don’t know why, but I never imagined having a backhoe. A farm excavator, yes. Perhaps even a small bulldozer - sure. Of course we have a tractor. But for some reason, I am particularly proud of owning a backhoe. Maybe it´s because of the variety of things it can do.
A backhoe has been called the Swiss Army knife of construction projects, and they really are. You have the huge shovel in the front and the bucket in the back and a lot of power in between. We bought a used one, a 2003, with lots of life still in it.
One of its first jobs was take apart a bridge. This bridge was made of Corteza and Tamarindo - both of these woods are very hard, so much so they survive just fine buried in mud over streams and rivers to make bridges. Pretty incredible really. One of our bridges was damaged by a storm and needed serious repair. The problem is, the wood from these trees has gotten very expensive. So, getting a log to fix a bridge could be in the thousands of dollars - whereas five years ago it was only 300 dollars - which gives you an idea of the rise in price of this wood.
So, we got a quote from someone to make two bridges from steel and concrete (one is the replacement, the other was needed too, so might as well) and it came to 6 million colones - or about 12,000 dollars. The amount of wood that we could salvage from the old bridge was 16,000 dollars. So, by using the wood in the bridge for other things, we actually manage to make a little and have new bridges, too! Without a backhoe, it would be impossible to get out the logs, so the backhoe already is paying for itself.
Posted in business in Costa Rica, wood | 2 Comments »
March 29th, 2008 fmorgan
We had a visit from a tree owner and spent a full day with them. They have been with us for a while and we have had numerous conversations with them. I always appreciate their visits because we have so much in common.
The good news is that after reviewing their trees they told us that there wasn’t anything they felt was wrong at all with them and they were thrilled at the size and quality. This of course was wonderful to hear. We do try very hard to do a great job and be diligent in following through with people, but as with all things that are part of nature, there are imperfections. I worry about imperfections. It is probably true that I don’t see the forest for the trees at times. If I see 5% of the trees not doing well it bothers me (and we replace them), and I can forget that means we have 95% growing very well. Our tree owners are always less critical than I am.
I think one of the reasons they gave us such high marks was that they visited trees that they own with someone else (people they bought with before they knew about us) and were much less pleased. In fact, nearly 50% of their trees were replanted after 2 1/2 years and it was obvious that the care just wasn’t being done. It appeared that their trees were planted and then ignored. Also, some trees were planted in areas that were not appropriate for those trees.
Worse yet, when they arrived, it was obvious that the area had just been brushed out, i.e. all the undergrowth removed, and all nearby trees owned by other people had brush about six feet tall, which will choke out the trees. An example is their acacia. Their acacia with the other people after 2 1/2 years is the same size as ours after 6 months! If there was ever a good example of the difference between growing trees correctly or not, this is one.
The bad news for them, of course, is that they have to deal with this, but also it is sad because we in Costa Rica need every bit of lumber we can get. To plant and not try your best to produce the best trees you can just seems to me to be so short-sighted. After all, it isn’t like there isn’t a good market — no, correct that, a great market — for the wood after it is grown.
On top of that, it is hard enough for people to have the confidence to have people in a foreign land grow trees for them, and to not do the job hurts everyone, not just your own business. Thankfully, we have many people who have visited us (and some visit yearly) and so have seen the plantations for themselves and can attest to our quality.
After all, it really is about quality. The price of wood is shooting up as the supply dwindles. For us, to achieve our goal of reforesting a significant amount of land, we have to make sure to meet the obligations we have to those who have trusted us to grow trees for them.
I am happy to be able to say it appears that we are acheiving more than they expected.
Posted in acacia, business in Costa Rica, conservation, finca, forest, forestry, investing, tree owners, trees, wood | No Comments »
March 20th, 2008 fmorgan
We have entered an agreement with Tropical Latitudes to be our importer of wood products into the USA. We were approached by Craig, who originally wanted us to plant trees for them from their profits and then found out that we also had products to sell.
To get to know them better, I flew up to Orlando to participate with them at a Home and Garden show. I was very happy at what I saw, and they survived having me as a guest for most of a week, which shows that truly they are cut out to survive in business.
What I most appreciate about Tropical Latitudes is their commitment to having everyone win. They will not deal with any company that does not treat their employees fairly nor do they work through brokers. In this way they can offer unique products to their customers at a very good price, and the makers of the products do well also.
It was very interesting at the show when a broker who wanted to be a supplier for Tropical Latitudes looked at a solid hardwood frog that our woodcarver had made that Craig was selling for 65 dollars. The broker said that the best he could sell it to Craig for was 60 dollars. This illustrates very well why it is so much better not to have several middlemen. However, because of the difficulty of getting things from the tropics to the USA, you are generally dealing with middlemen, and each one tends to want to double the price.
A positive thing for all those who have wanted to buy furniture from us is that now Tropical Latitudes can take the orders and arrange for the furniture to come up in the next shipment with everything else. This should make it possible to have furniture from us at a very reasonable price.
It is good news for our tree owners that not only are we doing great at producing products for the local market, but now we are selling into the USA as well.
Posted in business in Costa Rica, furniture, importing, investing, tree owners, wood | No Comments »
March 2nd, 2008 fmorgan
It occurred to me some time ago just how wasteful specialization is in the lumber business. In the traditional manner, a logger will find a group of trees to cut. He will not want to work with a single tree because he has to haul his equipment and get set up, is not something he makes money on. Loggers make money in the amount of wood they can process per day and the quality of that wood. Loggers who handle large volumes end up with a very large capital investment and speed is everything.
A logger will generally only take up to the first limbs. Furniture makers love figured wood, but sawmills hate wood with knots. They want clear trunks, because figured wood is hard to work with for the sawmills and dangerous, too. A large knot, for example where a limb connects, can catch in the saw and send the log flying. The other waste is that sawmills only want certain lengths, 8, 10, 12, 16, etc. The widths tend to be in standard sizes as well, based on even sizes.
Because of this efficiency, a tremendous amount of each tree goes to waste. Any pieces smaller around than 8 inches are considered scrap and so are segments of wood less than 8 feet long (really 99 inches to allow for checking on the ends of the wood).
Since we have our own furniture factory, we can use a lot more of the tree. Cabinet doors, a very good market for us, use many small pieces of wood. We also make spindles for chairs and banisters with a lathe. This uses limbs and other short pieces of wood. For even smaller pieces, we also have a market for wood crafts, bowls, coffee coasters, etc.
When we harvest a tree, we don’t leave much scrap out in the field. What little is left is used as mulch around the remaining trees. Because of this conservation of the resource, we can get up to 40% more out of every tree.
Because of our size, we can grow trees efficiently, and because of the wood factory, use more of the tree. This means every tree is used to its maximum potential, helping to ensure the plantation wood supply that takes pressure off the rainforest.
Posted in business in Costa Rica, conservation, forestry, furniture, resources, wood | No Comments »
February 8th, 2008 fmorgan
Now that our new furniture factory/millworks is taking off, a very important project is making kilns for drying lumber. Our part of Costa Rica is pretty humid most of the time, but in the USA homes are much drier, and so are homes in Guanacaste. To sell to these markets, we need to have kiln-dried wood. The nearest kiln is 2 hours away.
One thing that you tend to get any time you buy a farm is a corral, which is the name for an open-air barn. It might have a concrete floor if you are lucky. If so, by replacing the roof with clear plastic panels and enclosing with scrap wood and installing a few fans, you make a solar kiln. If you need more than that, you can supplement the heat with a wood fire or dry the air using a dehumidifier.
The great thing is that the basic construction is already done, and the location is usually very good as well, near to the road and house.
This is how it goes with many things — we might not make things totally pretty (except our furniture), but we get it done. One thing that you notice after a while here is that there is nothing left by the side of the road like up in the states. If you don’t use it, someone else will for sure, even after it is way past looking nice. And the remains can always be used for something else.
Posted in drying wood, kiln, off the grid, wood | No Comments »