Consumables
ABB paper solution boosts productivity by 17 percent
Monday 12. January 2009 - A comprehensive ABB process control solution for a European paper producer achieved substantial across-the-board benefits, including a 17 percent boost in production (without increasing machine speed) and 63 percent fewer errors.
Besides achieving a dramatic increase in productivity of 17 percent without increasing the speed of the paper machine – a common way to increase production in the paper industry – the solution substantially reduced process errors by 63 percent as well as paper losses by 10 percent and sheet breaks by 5 percent.
The solution is operating at St. Regiss Wansbrough paper mill in the United Kingdom. The mill has a production capacity of 150,000 metric tons of paper a year and is the largest manufacturer of coreboard in the country (coreboard is used to make kitchen and bathroom towels).
Based on ABBs System 800xA Extended Automation platform, the complete process control solution includes advanced quality control and scanning measurement systems, an air-water remoisturizing system and the integration of existing motor control centers, variable speed drives and instrumentation. ABB is also providing onsite and remote support services.
ABB has the worlds largest installed base of distributed control systems and is the number-one supplier of process automation systems to the pulp and paper industry – ARC Advisory Group, August 2008
By integrating the mills process control, quality management and automation systems with System 800xA, operators are able to control the entire plant through one user interface, using the same process stations, a common system architecture and optimal functionality.
“Mill personnel now have the visibility to get the process running efficiently, while the system monitors, coordinates and controls all machine functions,” says Chris Kellaway, mill operations manager at Wansbrough.
“Speed of response to potential problems has been improved. Now were able to make the right decision the first time,” says Mark Hughes, PM 5 production manager.
Breaking records
A recent posting at St. Regis announced that the weeks production record of almost 3,000 tons exceeded the previous record by more than 100 tons. Record uptime and a record low level of broke (trimmings etc) were also achieved in the same week.
By consolidating all its process control operations to System 800xA, St. Regis has achieved increased throughput, reduced downtime, improved product quality, decreased maintenance expense, improved process alarming and improved overall control.