By Wayne Nisley

In the heart of Somerset County, Pennsylvania, KBY Sawmill stands as a testament to resilience, adaptation, and a commitment to craftsmanship. Owned and operated by Noah Kinsinger and his son, Vernon (23 year old so called bachelor!), the sawmill has been a staple in the local timber industry for 40 years. It all began as a partnership among Kinsinger, Beachy, and Yoder (hence KBY). Noah’s dad was the Kinsinger, Beachy passed away from old age and Yoder got married and dropped out and it has now evolved into a family-run operation, with Vernon stepping up as Noah’s right-hand man.

KBY Sawmill does approximately one million board feet per year, operating with a manual Frick hand mill powered by a Detroit 671 engine, a setup that has proven reliable over the years. The log turner and the live deck are run by hydraulics. The mill is equipped with a six-inch Cornell edger and a Procut cut-off saw, the latter purchased through Showcase Equipment. “We highly recommend the Procut,” Noah says. “It’s a heavy-built cut-off saw, and we’re really happy with it.”

A Diverse Product Line

KBY Sawmill specializes in cutting a variety of hardwoods, with a focus on railroad ties, cants, and specialty cuts like wagon beds. The demand for railroad ties remains strong despite a tightening market, and the sawmill is able to move nearly all it produces. They also reclaim slabs, cutting them down to useful sizes and feeding them into a resaw to maximize efficiency.

One of the more unique products coming out of KBY Sawmill is cucumber lumber, a lightweight yet strong wood highly sought after for wagon beds. “I cut every cucumber log I can get,” Noah says. “It’s what the old-timer farmers always wanted for their wagon beds, and we keep that tradition alive.” The Cucumber lumber is similar to Poplar.

KBY also operates a 42-inch Montgomery hog to grind mulch for customers in the spring. Their slab wood finds its way to greenhouses, sugar operations, and outdoor furnace users, ensuring little waste in their process. Even sawdust is in high demand, with local farmers snapping it up as fast as it is produced.

Rebuilding After a Fire

Four years ago, KBY Sawmill faced a devastating fire that destroyed nearly everything except for their loaders. Faced with the challenge of rebuilding, Noah explored multiple options, weighing the costs and benefits of purchasing a new mill versus restoring an existing setup.

Initially, the search for a replacement was frustrating. New mills were costly, and many used options had wooden frames, which Noah wanted to avoid. With supply chain issues causing delays in 2021, waiting months for new equipment wasn’t a viable option either.

Then, through an unexpected lead from a firewood customer, Noah heard about an old Frick mill sitting unused behind someone’s shop on a trailer. Skeptical at first, he decided to take a look, assuming it would be in rough shape. What he found instead was a solid, all-steel mill with a Cornell edger—exactly what he had been searching for.

“I got so excited when I saw it,” Noah recalls. “It was all steel, barely worn, and exactly what we needed. Within five minutes, I knew I wanted that package deal.” The price was reasonable, and the mill had been well-maintained, making it a perfect fit for KBY Sawmill’s needs.

Now, the mill is set up more efficiently than before. The new layout allows workers to multitask, keeping production steady even when staffing is limited. The facility is also built with long-term durability in mind.

“We spent more to do it right the first time,” Noah explains. “We put a lot of concrete in, placed big I-beams in the concrete, and welded everything down properly. If we ever need to move anything, we just grind off the welds, and the floor is still level.” The I-beams in the concrete idea came from a friend and the Kinsingers highly recommend it. Vernon remarked that they haven’t regretted spending a bit more upfront to ensure a smoother work flow.

Lessons and Looking Forward

The Kinsingers have learned a lot through decades of experience and challenges. After losing a loader to an electrical short, they now flip the kill switch or disconnect cables on all their machinery at the end of each day as a safety precaution.

Their advice to young sawmill operators? Take it slow and grow into the business. “Going too big too fast can sink you,” Noah warns. “We were lucky to build gradually, and that’s made all the difference.”

Looking ahead, KBY Sawmill is considering an investment in a VacuTherm kiln and welcomes advice from others experienced with this kind of operation. They are also watching and are excited about the upcoming lumber auctions from Bright Star, hoping they become a useful resource for both buyers and sellers in the industry.

Through steady work and practical decisions, KBY Sawmill continues to provide quality lumber while making the most of every opportunity.

Thank you Vernon and Noah for allowing us to feature your business in EquipmentEdge!

Noah and Vernon would be happy to answer any questions you may have about their set up, operation, and equipment. They can be reached at (814) 634-5090.