System 800xA helps St. Regis Paper boost productivity by 17 percent

  • January 11, 2009
  • ABB
  • Case Study
January 11, 2009 - A comprehensive ABB process control solution using System 800xA as its integration platform has helped St. Regis Paper achieve substantial across-the-board benefits in one of its mills in the UK, 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 System 800xA 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. Regis’s 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 ABB’s 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. By integrating the mill’s 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 for 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 we’re able to make the right decision the first time,” says Mark Hughes, PM 5 production manager. Record-breaking results A recent posting at St. Regis announced that the week’s 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 on System 800xA, St. Regis has achieved increased throughput, reduced downtime, improved product quality, decreased maintenance expense, improved process alarming and improved overall control. ABB is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 120,000 people. Learn More

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