ABB will upgrade one of Neopak’s paper machines with latest distributed control system to enhance productivity and quality
The upgrade is set to advance Neopak’s transition to smart manufacturing and advanced process control
Following this initial implementation, ABB will develop a strategic roadmap for Neopak to integrate further digital solutions
Neopak, a leading manufacturer of containerboard and paper products, has renewed its partnership with global technology company ABB to upgrade the existing automation system at its Rosslyn Paper Mill in Pretoria, South Africa. The mill produces a variety of paper grades, including high-performance recycled liner and fluting, paper bags, core board, and plasterboard – essential materials for local industry applications such as building hardware, converters, and corrugators for packaging.
ABB will provide its latest ABB Ability™ System® 800xA distributed control system (DCS) for the mill’s Paper Machine 3 (PM3). The existing system, which includes the ABB Quality Control System (QCS), a current ABB DCS, and variable speed drives, will be upgraded to leverage new technological advancements and digital integrations. This upgrade will pave the way for Neopak to achieve optimal efficiency, productivity, and consistency through smart manufacturing.
Since its construction between 2007 and 2009, Neopak’s PM3 has been operational for over 15 years, with recent process adjustments boosting production to approximately 85,000 tons per annum. With ABB's upgrade, Neopak expects to significantly enhance production efficiency and product quality, enabling the mill to meet rising market demands for essential materials while upholding the highest standards of quality and sustainability.
Looking ahead, Neopak's future digital operations will emphasize advanced process control (APC), cyber security, and increased accuracy and efficiency across the entire machine and process. ABB has been tasked with defining a strategic digital roadmap for Neopak, facilitating a phased implementation of industry-leading digital solutions tailored for the pulp and paper sector, including enhanced cyber security and advanced process control (APC). Designed for peak performance, the ABB Ability System 800xA DCS will empower Neopak to adopt sophisticated control strategies and automation techniques, ensuring long-term operational efficiency.
“ABB is a champion for the South African pulp and paper industry and a trusted partner in our business, consistently delivering solutions that expand the boundaries of what's possible,” stated Nitesh Singh, Operational Director at Neopak. “Expanding our partnership with them is a natural step towards achieving our digitalization goals. Their digital toolkit, complemented by extensive industry expertise, is helping us unlock smart manufacturing at Neopak.”
“We believe it is very important to support Neopak in the next stages of its journey towards smart manufacturing,” said Arvin Ramjee, Account Manager, ABB Pulp and Paper, South Africa. “This project demonstrates ABB’s commitment to supporting manufacturers globally in achieving their digitalization objectives and optimizing operations for sustained success.”
System 800xA integrates with various process components, streamlining operations and optimizing production schedules. This, along with the critical next stages of Neopak’s digital transformation journey set to begin work in 2025, will result in increased efficiency and throughput for the manufacturer, alongside significant improvements in yield and paper quality. Additionally, the APC capabilities enable more precise management of the paper machine, leading to reduced waste. The system also fosters streamlined operations through a centralized platform, simplifying process monitoring and control for operators. This empowers them to make informed decisions and respond quickly to process variations.
The upgraded process controls and automation strategies will position Neopak for long-term success, while also granting them the flexibility to seamlessly integrate ABB's digital solutions for future optimization.
The project commissioning is expected to be completed in Q3 2025.
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