Helsinki, Finland – A leading Finnish chemical manufacturing plant has reported a 22% increase in production efficiency after upgrading its DCS with the ABB TU810V1 3BSE013230R1 controller. The upgrade, completed in Q4 2024, has also reduced process variability by 18%—a critical improvement for a facility that produces high-purity chemicals used in pharmaceuticals and electronics.
Chemical plants require precise, real-time control of processes like temperature, pressure, and chemical mixing to ensure product quality and safety. Prior to adopting the ABB TU810V1 3BSE013230R1, the Finnish plant’s aging DCS controller struggled with slow data processing, leading to delays in adjusting process variables. This resulted in inconsistent product batches and frequent downtime for manual recalibration.
“Our old controller couldn’t keep up with the complexity of our mixing processes,” said Jari Lehtonen, Plant Operations Manager at the chemical facility. “We’d often see delays of 2-3 seconds between sensor readings and control adjustments—enough to throw off the purity of our chemicals. Since installing the TU810V1 3BSE013230R1, that lag is gone. We’re now producing consistent batches, and our downtime for recalibration has dropped by 50%.”
The controller’s impact was felt across three key areas of the plant’s operations: Faster Process Adjustments: The 64-bit processor enabled real-time response to sensor data, reducing process variability by 18% and cutting rejected batches by 25%. Simplified Integration: The controller’s compatibility with the plant’s existing AC 800M DCS and third-party sensors eliminated integration delays, allowing the upgrade to be completed in just 3 days (down from the expected 1 week). Reduced Maintenance Costs: The TU810V1 3BSE013230R1’s built-in diagnostic tools alert teams to potential issues (like sensor drift) before they cause failures, reducing maintenance costs by €60,000 in the first 3 months.
“Chemical manufacturers face unique challenges—precision, safety, and efficiency are non-negotiable,” said Mikael Strom, ABB’s Regional Sales Director for Northern Europe. “The TU810V1 3BSE013230R1 is designed to address these challenges, and this success story in Finland shows how it can transform operations. We worked closely with the plant team to understand their needs, and the results speak to the value of our collaborative approach.”
The Finnish chemical plant plans to upgrade its second production line with the ABB TU810V1 3BSE013230R1 by mid-2025. For more details on how the controller supports chemical manufacturing and other industries, visit ABB’s customer success page.
