Ningbo, China – December 2025 – Ningbo Baoxin Stainless Steel Co., Ltd. and a leading Chinese paper manufacturer have announced significant operational improvements after upgrading their production lines with the ABB PFEA113-20 3BSE050092R20 tension controller. In metal rolling and paper production—industries where tension stability directly determines product flatness, thickness uniformity, and yield—the PFEA113-20’s robust design and advanced control capabilities have set a new standard for performance.
Tension Control Challenges in Metal & Paper Manufacturing
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Metal rolling and paper production face unique tension-related pain points that traditional controllers struggle to address:
- Ultra-Thin Metal Rolling: Producing stainless steel strips as thin as 30μm requires tension control within ±0.1% of the setpoint. Even minor fluctuations cause edge wave defects or material breakage, leading to costly downtime.
- High-Speed Paper Production: At speeds exceeding 1,000m/min, paper web tension variations result in wrinkles, breaks, and uneven winding. For high-grade printing paper, this translates to a 5-8% waste rate.
- Harsh Operating Environments: Metal rolling mills endure high temperatures (up to 80°C) and heavy vibration, while paper mills face high humidity and dust. Standard controllers often fail within 12-18 months under these conditions.
“We were struggling with 0.3% tension deviation in our ultra-thin stainless steel production,” said Zhang Wei, Technical Director at Ningbo Baoxin. “This led to a 2.5% defect rate and monthly losses of over RMB 500,000. We needed a controller that could withstand our mill’s harsh conditions while delivering pinpoint accuracy.”
A Zhejiang-based paper manufacturer faced similar issues: “Our old system required manual PID adjustments every 4 hours, and we still saw a 6% waste rate,” recalled Chen Yu, Production Manager. “The downtime for adjustments was costing us 10% of our daily output.”
ABB PFEA113-20: Engineered for Industrial Rigor
The ABB PFEA113-20 3BSE050092R20 tension controller addresses these challenges with features tailored to heavy-industry demands:
1. High-Precision Control for Critical Processes
With a steady-state accuracy of ±0.5% and dynamic accuracy of ±1% during acceleration/deceleration, the PFEA113-20 maintains tension stability even for ultra-thin materials. In metal rolling, it connects to up to 4 load sensors, monitoring and adjusting tension across multiple rolling stands in real time. For paper production, its 10ms response time eliminates web flutter at high speeds.
2. Rugged Design for Harsh Environments
The controller’s IP65-rated closed housing protects against dust, moisture, and oil—critical for metal and paper mills. It operates reliably within a temperature range of -10°C to +55°C and withstands vibration up to 1.5mm double amplitude (10-55Hz). Ningbo Baoxin reported zero controller failures in 18 months of operation, compared to 3-4 failures annually with their previous system.
3. Flexible Integration & Easy Operation
The PFEA113-20 supports DIN rail or panel mounting, fitting seamlessly into existing control cabinets. Its intuitive multi-language digital display allows operators to monitor tension sums, differences, and individual sensor signals at a glance. For paper mills, the controller’s Modbus RTU communication interface integrates with DCS systems, enabling remote parameter adjustment and data logging—eliminating the need for on-site manual tweaks.
4. Taper Tension for Uniform Winding
In paper winding and metal coil storage, the PFEA113-20’s taper tension control (linear/S-type) ensures consistent coil density, reducing edge damage and improving downstream processing efficiency. The paper manufacturer reported a 30% reduction in coil unwinding issues after implementing this feature.
Quantifiable Improvements for Manufacturers
Ningbo Baoxin’s results after 1 year of using the PFEA113-20:
- Defect rate dropped from 2.5% to 0.02%, saving RMB 6 million annually
- Stainless steel strip thickness tolerance narrowed to ±0.5μm, meeting aerospace-grade standards
- Maintenance costs reduced by 50% due to the controller’s self-diagnostic capabilities
The Zhejiang paper manufacturer achieved:
- Paper waste rate cut from 6% to 1.2%, saving 1,800 tons of pulp yearly
- Manual adjustment time eliminated, increasing daily output by 10%
- Web breakage reduced by 70%, cutting downtime by 24 hours per month
“ The ABB PFEA113-20 has transformed our ultra-thin rolling line,” Zhang Wei said. “We now produce 30,000 tons of high-precision stainless steel annually with a 99.98% yield rate—something we never thought possible with our old equipment.”
Chen Yu added, “The controller’s ease of use and reliability have made our operators’ jobs easier while delivering tangible cost savings. It’s a true plug-and-play solution for industrial tension control.”
Why ABB PFEA113-20 Stands Out in Heavy Industry
Unlike generic tension controllers, the PFEA113-20 is designed specifically for continuous-process industries, with a focus on durability, precision, and compatibility. Its ability to handle both low-tension (0.1N) and high-tension (up to 5,000N, expandable) applications makes it versatile across metal, paper, and other 卷材 (web) processing sectors.
As global demand for high-quality metal products and specialty paper grows, the ABB PFEA113-20 3BSE050092R20 tension controller is becoming the go-to choice for manufacturers aiming to improve yield, reduce waste, and enhance competitiveness in a crowded market.
