Church & Church Lumber Co. Sawmill

Precision Millwork for Your Exact Specifications

When standard lumber doesn't meet your manufacturing requirements, Church & Church's custom lumber manufacturing services deliver exactly what your production demands. For four generations, our Wilkes County sawmill has served manufacturers who require precision, consistency, and specialized materials that simply aren't available through standard distribution channels.

Your success depends on materials that perform exactly as specified. Our custom manufacturing capabilities ensure you get precisely what you need, when you need it.

Beyond Standard Grades: Custom Solutions for Manufacturers

At Church & Church, we understand that Manufacturing Mike needs more than just good lumber—he needs the right lumber for his specific application. Our custom manufacturing capabilities go far beyond standard offerings:

Precision Thickness Control

• Custom thickness options from 1/2" to 16/4"
• Tolerance precision to 1/64" for critical applications
• Consistent thickness across entire orders

Specialized Surface Processing

• S2S (surfaced two sides) for applications requiring precise thickness
• S4S (surfaced four sides) for ready-to-use components
• Specialized texturing options for architectural applications
• Custom profiles available upon request

Application-Specific Sorting

• Color matching for aesthetic consistency
• Grain pattern selection for strength and appearance
• Growth ring orientation for stability in specific applications
• Defect parameters tailored to your tolerance requirements

Specialty Products

• Quarter-sawn and rift-sawn material for stability and appearance
• Mixed species packages for varied application requirements
• Custom width and length sorting for yield optimization
• Proprietary grade sorts beyond standard NHLA specifications

Modern Equipment, Skilled Craftsmen

Successful custom manufacturing requires both advanced technology and experienced personnel. Church & Church combines both:

State-of-the-Art Equipment

• Precision sawing technology with computerized optimization
• Advanced planning equipment for consistent dimensions
• Computer-controlled drying with continuous monitoring
• Modern grading stations with optimal lighting and measurement tools

Experienced Production Team

• Skilled sawyers averaging 15+ years of experience
• NHLA-certified graders trained in custom specifications
• Kiln operators specialized in application-specific drying schedules
• Quality control personnel dedicated to maintaining your standards

This combination of technology and expertise ensures that your custom order meets specifications consistently from the first piece to the last, across multiple production runs.

Complete Process Control

Unlike suppliers who simply reprocess standard lumber, Church & Church controls the entire manufacturing process from log selection to final packaging:

Selective Log Procurement

Our timber buyers specifically source logs with characteristics suited to your application requirements, whether that means specific growth patterns, density characteristics, or origin considerations.

Customized Sawing Patterns

We adjust our sawing patterns to maximize the yield of your specific requirements, whether that means quartersawing for stability, flat sawing for consistent grain patterns, or specialized cutting for figure characteristics.

Application-Specific Drying

Our kiln operators develop and implement drying schedules tailored to your specific end use, balancing drying speed with quality considerations like stress relief, color development, and dimensional stability.

Precision Grading and Sorting

Our graders apply your exact specifications rather than simply following standard grades, ensuring every board meets your requirements for character, dimension, and performance characteristics.

Protective Packaging

Custom packaging options protect your investment during shipping and storage, from standard strapping to complete wrapping for moisture protection and damage prevention.

This complete process control enables us to deliver consistent quality that meets your exact specifications time after time.

Real Solutions for Manufacturing Challenges

Our custom manufacturing capabilities address common challenges faced by manufacturing operations:

Yield Optimization

Standard lumber grades often include material that doesn't meet your specific needs, forcing you to purchase excess material and generating costly waste. Our custom manufacturing provides precisely what you need, improving yield and reducing material costs.

Consistency Across Orders

Manufacturing requires consistency not just within orders but across multiple orders over time. Our documented specifications and quality control procedures ensure the lumber you receive this month matches what you received last month and what you'll receive next month.

Specialized Performance Requirements

From specific strength characteristics to unique appearance requirements, our custom manufacturing addresses performance needs that standard grades simply don't consider.

Production Efficiency

Receiving material already processed to your exact specifications eliminates in-house processing steps, reduces equipment wear, and improves production flow.

The Custom Manufacturing Process

Working with Church & Church for custom lumber manufacturing involves a collaborative process designed to understand and meet your exact needs:

1. Specification Development

We work with your team to understand your application requirements, tolerance needs, and production processes, developing detailed specifications that capture your exact requirements.

2. Sample Production and Approval

For new custom programs, we produce samples for your evaluation and testing, refining specifications based on your feedback until the material performs exactly as required.

3. Production Implementation

Your approved specifications become documented production standards, with quality control checks at every stage to ensure compliance.

4. Ongoing Monitoring and Adjustment

Regular communication ensures specifications evolve as your needs change, with formal review processes to maintain alignment with your manufacturing requirements.

5. Consistent Delivery Scheduling

Coordinated production and shipping schedules align with your manufacturing calendar, supporting just-in-time inventory management.

Frequently Asked Questions

What minimum quantities do you require for custom manufacturing?

Custom manufacturing typically requires minimum orders of one truckload, though exact minimums depend on the complexity of specifications and degree of customization. For established programs with regular ordering patterns, we can sometimes accommodate smaller volumes.

How long does it take to develop and implement a new custom specification?

Initial development typically requires 3-4 weeks, including sample production and refinement. Once specifications are approved, standard lead times for production range from 2-6 weeks depending on complexity, species, and current production schedule.

Can you match lumber from previous suppliers?

Yes, we regularly help manufacturers transition from previous suppliers by matching or improving upon existing specifications. Our process typically includes acquiring samples of your current material, analyzing key characteristics, and developing specifications that ensure a smooth transition.

Do you provide technical support for material selection and specification development?

Absolutely. Our technical team works with your manufacturing and engineering staff to understand application requirements and develop specifications that optimize both performance and cost. This collaboration continues throughout our relationship, ensuring specifications evolve as your needs change.

Can you provide certification for chain of custody or sustainable forestry practices?

Yes, Church & Church maintains various certifications for sustainable forestry practices. We can provide documentation regarding timber origin, processing methods, and compliance with environmental standards as required for your market or customer requirements.

How do you handle proprietary specifications?

We understand the competitive advantage custom materials provide. All customer specifications are treated as confidential, with access limited to personnel directly involved in production. We're happy to execute non-disclosure agreements for proprietary programs.

What species are available for custom manufacturing?

We specialize in Appalachian hardwoods including White Oak, Red Oak, Poplar, Maple, Cherry, Walnut, Hickory, and Ash. We also offer Appalachian softwoods including White Pine and Yellow Pine species. If your application requires species outside our standard offering, we can often source these through our extensive industry network.

Experience the Church & Church Difference

For manufacturers who demand precision, consistency, and specialized performance from their lumber products, Church & Church delivers custom solutions that enhance production efficiency and product quality. Contact our manufacturing solutions team today to discuss your specific requirements and discover how our custom lumber manufacturing capabilities can address your unique challenges.

Contact Information

Manufacturing Solutions Team
Phone: (336) 973-5700
Contact Us Online

Facility Location
798 New Browns Ford Road
Wilkesboro, NC 28697

Church & Church Lumber Company: Four generations of premium Appalachian hardwood manufacturing in Wilkes County, North Carolina. Delivering custom lumber solutions that enhance manufacturing efficiency and product quality.