Neopak Upgrades Automation with ABB for Smart Manufacturing

South African paper producer extends partnership with ABB to upgrade operations and accelerate digitalization
ABB will upgrade one of Neopak’s paper machines with latest distributed control system to enhance productivity and quality
The upgrade is set to advance Neopak’s transition to smart manufacturing and advanced process control
Following this initial implementation, ABB will develop a strategic roadmap for Neopak to integrate further digital solutions

Neopak, a leading manufacturer of containerboard and paper products, has renewed its partnership with global technology company ABB to upgrade the existing automation system at its Rosslyn Paper Mill in Pretoria, South Africa. The mill produces a variety of paper grades, including high-performance recycled liner and fluting, paper bags, core board, and plasterboard – essential materials for local industry applications such as building hardware, converters, and corrugators for packaging.

ABB will provide its latest ABB Ability™ System® 800xA distributed control system (DCS) for the mill’s Paper Machine 3 (PM3). The existing system, which includes the ABB Quality Control System (QCS), a current ABB DCS, and variable speed drives, will be upgraded to leverage new technological advancements and digital integrations. This upgrade will pave the way for Neopak to achieve optimal efficiency, productivity, and consistency through smart manufacturing.

Since its construction between 2007 and 2009, Neopak’s PM3 has been operational for over 15 years, with recent process adjustments boosting production to approximately 85,000 tons per annum. With ABB’s upgrade, Neopak expects to significantly enhance production efficiency and product quality, enabling the mill to meet rising market demands for essential materials while upholding the highest standards of quality and sustainability.

PM3 was commissioned in 2009 and will now reach new heights in efficiency and quality to meet market demands Image Neopak

Production will benefit from digital solutions including advanced process control APC and cyber security Image Neopak

Looking ahead, Neopak’s future digital operations will emphasize advanced process control (APC), cyber security, and increased accuracy and efficiency across the entire machine and process. ABB has been tasked with defining a strategic digital roadmap for Neopak, facilitating a phased implementation of industry-leading digital solutions tailored for the pulp and paper sector, including enhanced cyber security and advanced process control (APC). Designed for peak performance, the ABB Ability System 800xA DCS will empower Neopak to adopt sophisticated control strategies and automation techniques, ensuring long-term operational efficiency.

“ABB is a champion for the South African pulp and paper industry and a trusted partner in our business, consistently delivering solutions that expand the boundaries of what’s possible,” stated Nitesh Singh, Operational Director at Neopak. “Expanding our partnership with them is a natural step towards achieving our digitalization goals. Their digital toolkit, complemented by extensive industry expertise, is helping us unlock smart manufacturing at Neopak.”

“We believe it is very important to support Neopak in the next stages of its journey towards smart manufacturing,” said Arvin Ramjee, Account Manager, ABB Pulp and Paper, South Africa. “This project demonstrates ABB’s commitment to supporting manufacturers globally in achieving their digitalization objectives and optimizing operations for sustained success.”

Control system upgrades made by ABB will enable Neopak to raise its annual production outputs to around 85000 tons Image Neopak

System 800xA integrates with various process components, streamlining operations and optimizing production schedules. This, along with the critical next stages of Neopak’s digital transformation journey set to begin work in 2025, will result in increased efficiency and throughput for the manufacturer, alongside significant improvements in yield and paper quality. Additionally, the APC capabilities enable more precise management of the paper machine, leading to reduced waste. The system also fosters streamlined operations through a centralized platform, simplifying process monitoring and control for operators. This empowers them to make informed decisions and respond quickly to process variations.

The upgraded process controls and automation strategies will position Neopak for long-term success, while also granting them the flexibility to seamlessly integrate ABB’s digital solutions for future optimization.

The project commissioning is expected to be completed in Q3 2025.

ABB is a global technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. By connecting its engineering and digitalization expertise, ABB helps industries run at high performance, while becoming more efficient, productive and sustainable so they outperform. At ABB, we call this ‘Engineered to Outrun’. The company has over 140 years of history and more than 105,000 employees worldwide. ABB’s shares are listed on the SIX Swiss Exchange (ABBN) and Nasdaq Stockholm (ABB). www.abb.com

ABB’s Process Automation business automates, electrifies and digitalizes industrial operations that address a wide range of essential needs – from supplying energy, water and materials, to producing goods and transporting them to market. With its ~20,000 employees, leading technology and service expertise, ABB Process Automation helps process, hybrid and maritime industries outrun – leaner and cleaner. go.abb/processautomation

For more information please contact: Media Relations – Chris Brand, Phone: +44 (0) 7523919978
Email: chris.g.brand@gb.abb.com

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