The growing demand for high-efficiency wood processing is driving a surge in the popularity of advanced portable sawmills. These compact yet powerful machines offer unmatched versatility, giving users the ability to process timber on-site and on-demand.

With durable construction, precision-engineered components, and scalable functionality, a sawmill represents a strategic investment for sawmill operators, loggers, farmers, home builders, and woodworking professionals. Their reliability enables users to maintain profitability while adapting to production demands and market conditions.

Although sawmills are designed for operation by small teams of up to four people, many are run by a single operator. As a result, more sawyers are adopting portable sawmills optimized for solo operation.

These models offer efficient, user-friendly features that enable one person to manage the milling process effectively, reducing labor costs while maintaining high productivity. The units help reduce operator fatigue by using hydraulic log loaders, drag-back systems, and remote controls. With integrated hydraulics, a single operator can manage thousands of pounds of logs with minimal physical strain.

When production demands increase, the same equipment can be run by up to four people, boosting productivity. Converting a portable sawmill to a stationary setup is straightforward, offering flexibility to adapt to evolving operational needs.

One example is Runquist Sawmill Services in Mount Enterprise, Texas. Blending advanced milling capabilities with craftsmanship, the company produces a range of products, including live edge and straight edge planks, beams, super wide planks, fireplace mantels, book matched sets, pallet boards, and reclaimed wood. With expertise in hand-hewn lumber and custom cutting for client-supplied logs, Runquist demonstrates how portable sawmills can support high-quality production and personalized service.

According to Troy Runquist, owner of Runquist Sawmill Services, selecting the optimal sawmill for precision, efficiency, and volume was critical to his success.

“Accuracy was my top priority—I wanted to produce consistent, dimensionally exact lumber. If a customer requested 8/4 (two-inch thick) material, I wanted to deliver it precisely,” says Runquist.

Making a sawmill choice
Runquist spent two to three years researching equipment. “I think I looked at every sawmill under the sun at the time,” he said. He eventually selected a portable AC-36 sawmill from Cooks Saw, a leading manufacturer in portable bandsaw technology.

The diesel-powered unit is designed to handle bigger logs than most equipment in this category. Cooks’ sawmills are engineered with significantly more steel than the industry standard, resulting in a heavier, robust sawmill.

“It’s one of the most accurate mills out there. It consistently produces precise, reliable material, as long as it is set up properly,” said Runquist.

When Runquist started the business 16 years ago, he initially operated the AC-36 portable mill alone to keep overhead low. For the first four years, he ran the operation by himself, with occasional help stacking lumber.

“I’d work most of the day milling and then spend the rest stacking material and preparing loads for delivery to a larger sawmill,” he explained. “The physical demands were high, so equipment that minimized unnecessary movement was essential.”

When it comes to sawmill design, he said overall quality is often found in the details. Thoughtfully engineered features make a significant difference in day-to-day operation, particularly for solo operators.

“When you are younger, the physical work doesn’t bother you as much. But as you get older, you start to wish you'd invested a little more upfront in the available features to avoid all the grunt work later,” said Runquist.

Log loading and positioning
Efficiency for solo operators starts with loading and positioning heavy logs. Hydraulic loaders, turners, and clamps allow a single operator to move logs quickly and accurately into place.

The AC-36 sawmill, which can process timber up to 36” in diameter, is engineered to handle log weights up to 10,000 pounds.

“Their portable sawmills are the best I’ve seen in terms of lifting capacity, handling up to 10,000 pounds. That is a significant load for a mill, and I’ve never encountered a log that their cylinders couldn’t lift,” said Runquist.

Proper log positioning is essential for maximizing cutting efficiency and yield. Log turners allow operators to rotate logs into the optimal position, ensuring the widest possible cuts. Combined with heavy-duty clamps and squaring arms, the system supports smoother, more continuous operation.

“From the moment I see a log on the lift, I’m visually analyzing its shape, checking for straightness and irregularities. As it’s being rolled onto the deck, I’m already planning the best position for cutting,” he said.

Most logs are wider at the base than the top, so Runquist positions the narrow end toward the saw head and uses tapers to lift one end and ensure efficient center cuts.

“I can bring up either end of the log to position it exactly where I want it, then clamp it into place before cutting it,” he said.

To obtain the widest planks, he rotates oval-shaped logs onto their broadest side. Improper positioning in these cases would produce significantly narrower boards.

To increase production, the hydraulic system is engineered for fast clamp operation, allowing for quick log handling.

"Once you’re familiar with the controls, you save a lot of time setting up and moving to the next log. You're not waiting on hydraulic pressure or for the clamp to move—it’s just very fast," said Runquist.

Cutting speed control
Another advantage of the AC-36 sawmill is its cutting speed, which enables a solo operator to process logs at a high rate.

“With everything dialed in—sharp blades, tracking set correctly, and the right type of wood—you can make cuts as quickly as every 10 seconds, sometimes even faster with softwoods,” said Runquist.

For one operator, cutting and stacking at that pace may not be practical, so the mill includes adjustable head speed controls. According to Runquist, the saw head can be set to virtually any speed. This is invaluable when training new sawyers. Beginners can start slow and gradually increase speed as they get more experience.

When his sons joined the business, he lowered the speed so they could learn gradually without damaging equipment.

Over time, Runquist and his sons added three additional Cooks' sawmills to the operation. In addition to the original AC-36, they now have a second AC-3651, a custom-built electric AC-4440 that handles logs up to 44 inches in diameter and 32 feet long, and a gas-powered SW52 that handles logs up to 52 inches in diameter. They also operate a large electric edger, a Cat Claw bandsaw blade sharpener, and a Dual Tooth Setter.

Drag back capability
A drag-back system enhances efficiency by automatically returning cut lumber to the operator or outfeed area. Developed in response to customer demand in the 1990s, this feature has become an industry standard.

After a cut, “fingers” engage below the blade as the saw head moves back, pulling the board toward the operator. This reduces downtime and operator fatigue.

Kevin Casey, founder of Freeport, Florida-based Freeport Sawmill, said, “After the cut, the drag back system pulls the cut lumber back so it can be stacked or removed from the machine. You can kick back one board or the whole log after you cut it, and if you have other people helping you, they are busy right away.”

A mechanical contractor for over 40 years, Casey founded Freeport Sawmill several years ago. The company operates both a high-capacity production mill and a system for cutting large, wide slabs. While capable of standard output, the sawmill focuses on custom and high-end orders.

After using a manual mill the first year, Casey, now in his 60s, upgraded to an AC-36 hydraulic mill with more automation.

“I wanted to mill full-time and knew that a fully hydraulic system would ease my workload while improving my production and the quality of my cuts,” said Casey.

Casey is the primary operator and receives assistance with kiln drying, stacking, and prep. He’s also supported by an experienced sawyer.

Although the AC-36 is still the primary sawmill in his operation, demand for wider cuts such as those for tabletops, bar tops, and kitchen islands prompted the purchase of a Super Wide AC-62, Cooks' largest mill, approximately two and a half years ago.

“The purchase was made with the expectation that it would prove its value over time, and it has,” said Casey. “With the sale of the next large log, the investment will have paid for itself.”  

Casey appreciates the cost-effectiveness of maintenance. “With many of their parts readily available, maintaining the sawmills costs much less than comparable equipment,” he said.

“They’ll custom-build anything, reinforcing it if needed. If you want a motor beyond the recommended horsepower, they will accommodate that too,” said Casey.

By integrating automation, precision, and labor-saving features, portable sawmills offer unmatched efficiency for both single and multi-operator setups. This flexibility ensures consistent, high-quality lumber production and long-term value.

For more information phone 800-473-4804 or visit cookssaw.com.