After evaluating solutions from Siemens and Rockwell Automation, UPM selected the ABB PFEA111-65 3BSE050090R65 tension control module for its high-precision tension regulation, adaptive control algorithms, and seamless integration with existing automation systems. Key features addressing the mill’s pain points include:
- High-Precision Tension Regulation: The ABB PFEA111-65 3BSE050090R65 module uses advanced load cell technology and proportional-integral-derivative (PID) control to maintain tension accuracy within ±1%. This eliminates the large tension fluctuations that caused paper breaks and uneven thickness, ensuring consistent product quality across all paper grades.
- Adaptive Control Algorithms: The module’s adaptive control logic automatically adjusts tension parameters based on real-time data such as paper grade, basis weight, and production speed. This eliminates the need for manual adjustments, reducing operator intervention by 70% and ensuring optimal performance even as production conditions change.
- Seamless System Integration: Supporting Modbus TCP/RTU and Ethernet/IP protocols, the PFEA111-65 3BSE050090R65 integrates seamlessly with UPM’s existing ABB AC800M DCS and SCADA systems. This plug-and-play compatibility minimized installation time, allowing the upgrade to be completed in just 10 days per production line without disrupting ongoing operations.
- Advanced Diagnostic Capabilities: The module provides real-time status monitoring and detailed fault alerts for load cells, wiring, and power issues. Technicians can access diagnostic data remotely via a secure web interface, reducing troubleshooting time by 80% and eliminating 90% of unplanned downtime related to tension control systems.
- Rugged Industrial Design: Built to withstand the harsh papermaking environment, the PFEA111-65 3BSE050090R65 features an IP20-rated enclosure and operates reliably in temperatures ranging from -10°C to 60°C. Its solid-state design reduces mechanical wear, increasing the mean time between failures (MTBF) to 150,000 hours and cutting maintenance costs by 60%.
Results: Reduced Waste, Increased Efficiency, Lower Costs
Six months after deploying the ABB PFEA111-65 3BSE050090R65 tension control module, UPM’s Helsinki mill achieved significant operational improvements:
| Metric |
Before ABB PFEA111-65 3BSE050090R65 |
After ABB PFEA111-65 3BSE050090R65 |
Improvement |
| Paper Waste Rate |
8.2% |
2.62% |
68% Reduction |
| Production Throughput |
900 Tons/Day |
1,152 Tons/Day |
28% Increase |
| Monthly Unplanned Downtime |
8-10 Hours |
1-2 Hours |
85% Reduction |
| Annual Waste & Rework Costs |
€4.05 Million |
€1.296 Million |
68% Reduction |
| Annual Maintenance Costs |
€280,000 |
€112,000 |
60% Reduction |
“The ABB PFEA111-65 3BSE050090R65 module has transformed our papermaking operations,” Lehtinen said. “During a recent 30-day production run of high-grade printing paper, we achieved a waste rate of just 2.1%—the lowest in the mill’s history. The module’s adaptive control has also allowed us to run lines at full capacity, helping us meet customer demand without compromising quality.”
Anna Koskinen, ABB’s European Pulp & Paper Automation Product Manager, commented: “Papermakers face increasing pressure to reduce waste, improve efficiency, and produce high-quality products. The ABB PFEA111-65 3BSE050090R65 tension control module delivers the precision and reliability needed to meet these challenges, helping mills optimize operations and boost profitability.”
UPM plans to deploy the ABB PFEA111-65 3BSE050090R65 tension control module across 12 additional paper mills in Europe and North America by 2033, targeting a 65% group-wide reduction in paper waste and a 25% increase in production throughput.
