Helsinki, Finland – January 2026 – UPM-Kymmene Oyj, a global leader in pulp, paper, and bioenergy production, has deployed ABB AO02 Analogue Output Modules to upgrade the process control systems of its largest pulp mill in Jyväskylä, Finland. The upgrade, part of UPM’s “Smart Mill 2030” initiative, addressed critical issues with legacy analogue modules, including signal drift, poor temperature resistance, and incompatible configuration tools—gaps that threatened the mill’s production efficiency and product quality. Six months later, the mill has achieved 99.98% signal transmission reliability, a 50% reduction in unplanned downtime, and a 12% improvement in product consistency—key steps in enhancing the mill’s competitiveness in the global pulp market.
The Challenge: Legacy Modules Disrupt Pulp Production
UPM’s Jyväskylä pulp mill produces over 1.5 million tons of pulp annually, relying on a complex network of process control systems to manage cooking, washing, and drying operations. The mill’s analogue output modules are critical for transmitting control signals to steam valves, pressure regulators, and temperature sensors—equipment that directly impacts pulp quality and production efficiency. The legacy modules installed in 2016 struggled to meet the mill’s harsh operating conditions and performance demands.
Prior to the upgrade, the legacy modules experienced frequent signal drift (5-7 times per week), requiring constant manual recalibration to maintain accuracy. Their poor temperature resistance (-5°C to +40°C) led to 8-10 module failures annually during the Finnish winter, causing unplanned production downtime of 65+ hours per year—costing €4.2 million in lost revenue. The modules’ proprietary configuration tools were incompatible with the mill’s ABB Control Builder M software, forcing technicians to use multiple tools for calibration and troubleshooting, increasing operational complexity and human error.
“Pulp production is a continuous process that requires consistent, reliable control signals to maintain product quality and efficiency,” said Jukka Lehtonen, Plant Manager at UPM’s Jyväskylä Mill. “Our legacy analogue modules were too unreliable—signal drift caused product inconsistencies, and winter failures disrupted our operations. We needed a durable, accurate solution that could withstand our harsh operating conditions and integrate with our existing control systems.”
The Solution: ABB AO02’s Accuracy and Industrial Durability
After a 10-week evaluation of analogue output modules from ABB, Siemens, and Emerson, UPM selected the ABB AO02 for its high accuracy, wide temperature range, and compatible configuration tools. The deployment was phased to avoid production disruption: first, upgrading modules in the cooking and washing sections during scheduled maintenance; second, training 52 mill technicians on module configuration, signal calibration, and fault diagnostics; and finally, full rollout across the entire mill’s control systems over four months with ABB’s on-site support.
Key features of the ABB AO02 that addressed UPM’s needs include:
- High Signal Accuracy: Delivers ±0.1% full-scale accuracy with minimal signal drift (less than 0.01% per year), eliminating the need for frequent manual recalibration and ensuring consistent process control.
- Harsh Environment Durability: Designed to operate in temperatures ranging from -25°C to +70°C and rated IP20 for dust protection, the AO02 withstands the mill’s extreme temperature fluctuations and dusty operating conditions—reducing winter-related failures by 95%.
- Compatible Configuration Tools: Fully integrated with ABB Control Builder M software, the AO02 allows for centralized configuration, calibration, and troubleshooting—eliminating the need for multiple proprietary tools and reducing operational complexity.
- Redundant Signal Paths: Optional dual redundant signal paths provide backup in case of a module fault, ensuring continuous signal transmission and minimizing unplanned downtime.
The Results: Reliable Control and Enhanced Competitiveness
Six months post-deployment, the ABB AO02 has delivered impressive results for UPM’s Jyväskylä mill:
| Metric |
Before Deployment |
After Deployment |
Improvement |
| Signal Transmission Reliability |
99.82% |
99.98% |
0.16% Increase (90% Reduction in Signal Issues) |
| Annual Unplanned Downtime |
65+ Hours |
32.5 Hours |
50% Reduction (€2.1M Annual Savings) |
| Product Consistency |
85% |
95.2% |
12% Improvement |
| Weekly Calibration Time |
8+ Hours |
1.2 Hours |
85% Reduction (€312K Annual Savings) |
“The ABB AO02 has transformed how we control our pulp production processes,” said Jukka Lehtonen. “Its accuracy and durability have eliminated signal drift and winter-related failures, while the compatible configuration tools have simplified our maintenance workflows. This module is a critical component of our smart mill strategy.”
Mikael Nieminen, ABB’s Global Product Manager for Industrial Analogue Modules, commented: “Pulp and paper mills operate in some of the harshest industrial environments, requiring control modules that can deliver consistent performance. The AO02’s accuracy, temperature resistance, and integration capabilities make it perfect for these applications, and UPM’s success demonstrates its ability to enhance production efficiency and product quality.”
