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’s 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 Started with a Conversation
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’ struggles. “I’d heard stories where operators were raising and lowering the skyline every cycle,” he recalls. “That 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’s also hard on the brakes and clutches of the yarder.”
The issue, as Grant points out, is that some tower yarders weren’t 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’s terrain and working style.
Collaboration and Credit
Grant credits much of the inspiration to other local contractors Matt and Bill Winmill of Gillian Logging, who faced similar challenges. “Matt and Bill came up with a clever solution that really caught my eye,” Grant says. “They designed it themselves, and I thought, why not see if we can incorporate something like that into our own operation?”
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.
Smart Engineering and a Simple Addition
At the heart of the project was a goal: give the hauler operator direct, precise control of the skyline without relying on the tower’s braking system.
The DC Equipment 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. “It’s a minimal extra cost, but it saves a heap of time,” Grant says. “We only need to walk the strawline once from the tail hold to the hauler, after that it’s all ready to go.”
Real-World Results
Grant’s son, Matt Stewart, who operates the Madill 172 tower yarder, says the system has been transformative.
“He loves being able to control the tension through the eight winch settings,” Grant notes. “It’s given us access to wood in places we would’ve struggled to reach before.”
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. “The stems are placed directly where the Falcon Claw can grab them,” Grant explains. “It’s made a huge difference in safety and efficiency.”
Dual Purpose, Maximum Uptime
One of the biggest advantages is versatility. When the Madill 172 isn’t pulling wood, the custom Falcon Winch Assist can be repurposed for ground based or skidder operations.
“That’s the beauty of it,” says Grant. “If the hauler’s 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.”
From Forest to Future
For Stewart Logging, the project represents more than a mechanical upgrade, it’s a story of innovation born in the bush.
“It’s a good feeling seeing something you’ve talked about turn into reality,” Grant reflects. “And to see it working every day, doing what we hoped it would, that’s the best part.”
The collaboration is a clear example of Falcon’s innovation philosophy: smart ideas driven by real world experience.
“Operators like Grant and Matt are the reason Falcon machines keep evolving,” says DC Equipment Spokesperson Tom Filmer. “They’re the ones who see what’s possible, we just help make it happen.”
