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ABB Modernizes Billerud Paper Machine Automation
Upgrade of automation, quality control and drive systems at Gävle mill prepares production for AI-enabled optimization and improved energy efficiency.
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In the pulp and paper industry and industrial automation systems sector, ABB has signed an agreement with Billerud to modernize Paper Machine 5 at the Gävle mill in Sweden. The project upgrades core automation, quality control and drive technology to improve operational stability, cyber security and resource efficiency in packaging board production.
Automation Upgrade for High-Volume Packaging Board Production
The Gävle mill produces liquid packaging board and liner used in global food and consumer goods applications. Across Billerud’s network, output corresponds to the equivalent of approximately 200 million containers per day, making machine reliability and quality consistency critical.
The modernization brings several systems onto ABB’s latest automation platforms, including:
- ABB Ability™ System 800xA® distributed control system
- New-generation AC 800M controllers
- Updated quality control system (QCS)
- Refreshed drive technology
By consolidating these components within a unified automation architecture, the mill gains improved data handling, clearer operator interfaces and faster diagnostics. This enables tighter process control during grade changes and production shifts.
Strengthening Cyber Security and Operational Resilience
A key objective of the upgrade is reinforcing the mill’s cyber security posture. Legacy hardware and software platforms can introduce vulnerabilities and limit integration with modern digital tools. Migrating to current-generation controllers and automation systems enhances system resilience while ensuring compliance with evolving industrial cyber security requirements.
Improved system redundancy and standardized hardware also reduce downtime risk and simplify long-term maintenance.
Resource Efficiency and Quality Control
Modernized quality control and drive systems contribute directly to energy efficiency and reduced raw material consumption.
Greater precision in controlling basis weight, moisture and other board parameters helps minimize deviation from quality targets. This reduces overuse of fiber and energy during corrections while maintaining product specifications.
Integrated drive technology further supports stable web handling and optimized machine speed control, both essential for consistent board formation and reduced waste.
Foundation for Advanced Process Control and AI
Beyond immediate performance improvements, the new automation environment provides the infrastructure required for AI-enabled optimization and advanced process control.
With standardized data flows and enhanced computational capability, Billerud can introduce advanced analytics tools to support predictive maintenance, process stabilization and continuous efficiency gains. The system’s flexibility also allows faster introduction of new board grades as market demand for fiber-based packaging evolves.
Long-Term Modernization Strategy in Pulp and Paper
For high-capacity paper machines operating in competitive global markets, phased modernization of automation and drive systems is a common strategy to extend asset life while improving digital readiness. Rather than replacing the full mechanical installation, upgrading control layers can deliver measurable gains in stability, safety and efficiency.
With the modernization of Paper Machine 5, Billerud establishes an automation platform designed to meet current production requirements while supporting long-term digital transformation in packaging board manufacturing.
www.abb.com
Strengthening Cyber Security and Operational Resilience
A key objective of the upgrade is reinforcing the mill’s cyber security posture. Legacy hardware and software platforms can introduce vulnerabilities and limit integration with modern digital tools. Migrating to current-generation controllers and automation systems enhances system resilience while ensuring compliance with evolving industrial cyber security requirements.
Improved system redundancy and standardized hardware also reduce downtime risk and simplify long-term maintenance.
Resource Efficiency and Quality Control
Modernized quality control and drive systems contribute directly to energy efficiency and reduced raw material consumption.
Greater precision in controlling basis weight, moisture and other board parameters helps minimize deviation from quality targets. This reduces overuse of fiber and energy during corrections while maintaining product specifications.
Integrated drive technology further supports stable web handling and optimized machine speed control, both essential for consistent board formation and reduced waste.
Foundation for Advanced Process Control and AI
Beyond immediate performance improvements, the new automation environment provides the infrastructure required for AI-enabled optimization and advanced process control.
With standardized data flows and enhanced computational capability, Billerud can introduce advanced analytics tools to support predictive maintenance, process stabilization and continuous efficiency gains. The system’s flexibility also allows faster introduction of new board grades as market demand for fiber-based packaging evolves.
Long-Term Modernization Strategy in Pulp and Paper
For high-capacity paper machines operating in competitive global markets, phased modernization of automation and drive systems is a common strategy to extend asset life while improving digital readiness. Rather than replacing the full mechanical installation, upgrading control layers can deliver measurable gains in stability, safety and efficiency.
With the modernization of Paper Machine 5, Billerud establishes an automation platform designed to meet current production requirements while supporting long-term digital transformation in packaging board manufacturing.
www.abb.com
