“Once your kiln is installed, we are there, on-site, to help you train your operators for several weeks. We want to make sure that you are getting the most out of your system.” – Nick Girardi, Inside Sales Manager, KDS Windsor
KDS Windsor, located in Hendersonville, NC, has dedicated mechanical crews with over 100 skilled professionals in the field.
A Legacy Of Leadership And Craftsmanship
KDS Windsor, based in Hendersonville, NC, is a leading manufacturer of advanced lumber drying systems and a rapidly expanding industrial mechanical services provider. Originally founded as KDS by Rob Girardi in 1992, the company has evolved from a one-man operation into an international force in kiln technology and industrial mechanical services.
“When my dad, Rob, struck out on his own in 1992, he was a one-man show,” said Nick Girardi, Inside Sales Manager for KDS Windsor. “He started with consulting and parts sales. Then in 1999, he brought on Chris Chambers and Chuck Womack for kiln installation, manufacturing and burner engineering. Soon after, Robert Elliot asked if they could build a kiln for his sawmill, and they did, before even having a proper facility to build it in. Once that kiln was installed at Elliot Lumber, there was no looking back.”
A KDS Windsor fabricator aligns and torques components during assembly, combining craftsmanship with rock-solid mechanical know-how.
Engineering Growth Through Partnership
In 2008, KDS partnered with Windsor Engineering of New Zealand. “Windsor had acquired the license from Andy Pollard, who developed the Continuous Dry Kiln (CDK) technology,” said Nick. “They needed a U.S. partner, and we needed a larger engineering team and access to that license. So, we teamed up and began operating as KDS Windsor.”
Since forming that partnership, KDS Windsor has installed more than 100 CDKs worldwide. What began as a field-support team has since evolved into a full-service mechanical division known as the Industrial Mechanical Group, which serves mills of all types, whether they own KDS equipment or not.
“Once your kiln is installed, we are there, on-site, to help you train your operators. We want to make sure that you are getting the most out of your system,” said Nick.
Pictured is a rendering of KDS Windsor’s 50MM BTU Green Sawdust Gasifier.
The Industrial Mechanical Advantage
Today, KDS Windsor operates dedicated mechanical crews with over 100 skilled professionals in the field. Their expertise spans kiln rebuilds, equipment installations, fabrication and welding and material conveying systems.
“This is a major differentiator,” said Nick. “In an industry where most manufacturers outsource or do not offer support services at all, we not only build the equipment, we maintain it.”
Backed by in-house fabrication, fully equipped service trucks, and seasoned kiln experts, the Industrial Mechanical Group combines boots-on-the-ground speed with deep technical knowledge. “Once your kiln is installed, we are there on-site for several weeks to train your operators,” Nick explained. “We also offer remote support for new staff, and when it is time for recommissioning, our engineers return to recalibrate all mechanical devices and sensors, balance airflow and heat distribution, optimize the full system and train your operators.”
“Once your kiln is installed, we are there on-site for several weeks to train your operators. We also offer remote support for new staff,” stated Nick Girardi, inside sales manager for KDS Windsor.
Innovation Spotlight: The 50MM BTU Green Sawdust Gasifier
KDS Windsor’s latest leap forward comes in the form of its most advanced and powerful system to date, the 50MM BTU Green Sawdust Gasifier.
Engineered for scale, precision and performance, this burner was designed to tackle one of the biggest challenges in direct-fired green fuel systems: carryover.
Historically, green fuel gasifiers faced skepticism due to ash carryover into kilns and downstream equipment, which could reduce lumber grade, increase maintenance, corrode structures and raise fire risk. The new KDS Windsor design changes that narrative entirely.
A KDS Windsor welder fabricates components inside a large industrial shop.
Precision-Engineered Performance
The 50MM BTU gasifier features a 10-row grate system, each row generating 5MM BTUs, with a dual extraction system and two independently controlled ignition blowers feeding into a common hot duct. “That innovation ensures even gasification across the entire footprint, something never achieved at this scale,” said Nick.
The true breakthrough lies in pressure stabilization. “Pressure swings cause what we call fuel slides, which lead directly to carryover,” Nick explained. “By integrating advanced injection technology, we’re maintaining steady combustion pressure and achieving flatlined temperature data, a milestone in burner safety and consistency.”
Throughout the years, KDS Windsor has continuously refined its green sawdust gasifier. Each small, incremental improvement has compounded into major gains in efficiency, stability and performance, proving that progress often comes one precise adjustment at a time.
“The 50MM BTU Green Sawdust Gasifier is not just another burner. It is a technological leap that redefines what is possible with direct-fired biomass systems,” said Nick.
KDS Windsor’s flagship Performance Series CDK
Automation and Intelligence Built In
Every system input, from under-grate dampers to combustion fan speeds, ties into the DrySpec control system, which optimizes performance over long run times.
“The burner adjusts over time,” said Nick. “It adjusts dampers and airflow as the fuel bed compacts. A fully automated idle door helps maintain optimal temperatures for faster restarts and improved energy efficiency. The taller stack height improves suction for quicker heat recovery, another big win for uptime.”
Designed for a throughput of 160 million board feet annually, the system has delivered consistent outputs closer to 200 million, a 25 percent increase over target.
“Even longtime skeptics have been impressed,” Nick said. “After inspecting the system, one international partner remarked how remarkably clean it was, and now they are considering adopting the technology abroad.”
Hendersonville, NC Manufacturing Facility
Redefining the Future of Biomass Systems
The 50MM BTU Green Sawdust Gasifier is more than an upgrade. It is a redefinition of performance, safety and sustainability. “With near-zero carryover, automated combustion control and unmatched energy efficiency, KDS Windsor has once again raised the bar for biomass-fired kiln systems,” stated Nick.
The same engineering breakthroughs have now been integrated into the company’s 25MM, 30MM, 35MM, and 40MM BTU models, delivering cleaner combustion, tighter control and higher efficiency across the entire gasifier lineup.
Philadelphia, MS Manufacturing Facility
A Trusted Name Since 1992
From a single craftsman’s vision to a world-class engineering and service powerhouse, KDS Windsor has spent more than three decades shaping the future of lumber drying.
With unmatched field experience, relentless innovation and a customer-first philosophy, KDS Windsor continues to set the standard for kiln performance, reliability and support.
KDS Windsor is a proud member of the Mississippi Lumber Manufacturers Association, Southeastern Lumber Manufacturers Association, Western Wood Products Association, Southern Forest Products Association, Indiana Hardwood Lumbermens Association, the Appalachian Lumbermen’s Club and the West Coast Dry Kiln Association.
For more information, visit www.kdskilns.com or call 828-891-8115.
