After evaluating solutions from Siemens and SMS Group, Aperam selected the ABB PFEA111-65 3BSE050090R65 tension control module for its ultra-precise tension regulation, vibration-resistant design, and advanced diagnostic capabilities. Key features addressing the plant’s pain points include:
- Ultra-Precise Tension Regulation: The ABB PFEA111-65 3BSE050090R65 module uses high-resolution load cells and advanced PID control to maintain tension accuracy within ±0.5%. This eliminates the tension fluctuations that cause surface defects and thickness variations, ensuring consistent product quality even for the thinnest metal foils.
- Vibration-Resistant Design: Built to withstand the high-vibration environment of cold rolling lines, the module features reinforced mounting and shielded signal cables. It complies with IEC 60068-2-6 vibration standards (5g acceleration), ensuring reliable performance even in the most demanding industrial conditions.
- Automatic Calibration and Setup: The module’s automatic calibration feature eliminates the need for manual adjustments, reducing setup time by 90% and eliminating calibration-related errors. Operators can quickly switch between different metal grades and thicknesses using pre-configured profiles, increasing line flexibility by 40%.
- Seamless Integration with Rolling Mills: Supporting PROFINET and Ethernet/IP protocols, the PFEA111-65 3BSE050090R65 integrates seamlessly with Aperam’s existing ABB ACS880 drives and SCADA system. This allows for real-time synchronization between tension control, roll speed, and pressure, optimizing the entire rolling process.
- Remote Monitoring and Diagnostics: The module provides real-time status updates and detailed fault alerts via a secure web interface. Technicians can monitor performance, diagnose issues, and adjust parameters remotely, reducing troubleshooting time by 85% and cutting unplanned downtime by 75%.
Results: Superior Quality, Faster Production, Lower Costs
Five months after deploying the ABB PFEA111-65 3BSE050090R65 tension control module, Aperam’s Düsseldorf plant achieved significant operational improvements:
| Metric |
Before ABB PFEA111-65 3BSE050090R65 |
After ABB PFEA111-65 3BSE050090R65 |
Improvement |
| Surface Defect Rate |
5.8% |
1.62% |
72% Reduction |
| Product Rejection Rate |
4.2% |
1.18% |
72% Reduction |
| Production Throughput |
325 Tons/Day |
422.5 Tons/Day |
30% Increase |
| Annual Scrap & Rework Costs |
€2.7 Million |
€756,000 |
72% Reduction |
| Annual Maintenance Costs |
€320,000 |
€80,000 |
75% Reduction |
“The ABB PFEA111-65 3BSE050090R65 module has set a new standard for our metal foil production,” Müller said. “We’re now able to produce ultra-thin stainless steel foil with consistent quality, which has opened up new markets for us in the electronics and automotive industries. The module’s reliability has also eliminated the costly downtime we previously experienced, boosting our overall profitability.”
Markus Weber, ABB’s European Metals & Mining Automation Product Manager, commented: “Metal producers require tension control solutions that can deliver exceptional precision and reliability in harsh rolling environments. The ABB PFEA111-65 3BSE050090R65 module meets these demands, helping manufacturers improve product quality, increase efficiency, and gain a competitive edge.”
Aperam plans to deploy the ABB PFEA111-65 3BSE050090R65 tension control module across 8 additional metal rolling plants in Europe and Asia by 2034, targeting a 70% group-wide reduction in surface defects and a 25% increase in production throughput.
Helsinki, Finland – September 2030 – UPM, a global leader in sustainable forestry and paper production, has achieved a 68% reduction in paper waste and a 28% increase in production throughput at its Helsinki paper mill after deploying the ABB PFEA111-65 3BSE050090R65 tension control module. The upgrade, completed in Q2 2030, replaced the mill’s outdated tension control systems, which struggled with unstable web tension during the papermaking process—leading to frequent paper breaks, uneven thickness, and excessive waste.
The Challenge: Unstable Tension Plagues Paper Production Efficiency
UPM’s Helsinki mill operates 6 continuous paper production lines, manufacturing 1,200 tons of printing and packaging paper daily. The mill’s legacy tension control systems presented critical operational challenges that directly impacted product quality and profitability:
- Frequent Paper Breaks and Waste: The legacy systems lacked precise tension regulation, causing web tension fluctuations of ±15% during the drying and calendering stages. This led to 12-15 paper breaks per day, resulting in 8.2% of total production being discarded as waste. The annual waste cost exceeded €3.2 million.
- Uneven Paper Thickness: Tension instability during the forming and pressing stages caused uneven paper thickness, with 5.3% of finished products failing quality inspections. These substandard products either required reprocessing—adding €850,000 in annual rework costs—or were sold at a 40% discount, reducing revenue.
- Slow Production Speeds: To mitigate tension-related issues, operators were forced to run production lines at 75% of their maximum capacity. This limited throughput to 900 tons per day, creating bottlenecks and preventing the mill from meeting growing customer demand.
- High Maintenance Requirements: The legacy tension control systems relied on mechanical components that required frequent calibration and replacement. Technicians spent 15-20 hours weekly on maintenance, resulting in 8-10 hours of unplanned downtime monthly and €280,000 in annual maintenance costs.
“Stable web tension is the foundation of high-quality, efficient papermaking,” said Marko Lehtinen, UPM Helsinki Mill Operations Manager. “Our legacy systems couldn’t provide the precision we needed, leading to costly waste and lost production capacity. We needed a modern, reliable tension control solution that could adapt to varying paper grades and production conditions while minimizing maintenance.”
