Neopak expands partnership with ABB to drive digital transformation

SOUTH AFRICA – Neopak, a leading manufacturer of containerboard and paper products, has renewed its collaboration with global technology leader ABB to enhance operations and accelerate digital innovation at its Rosslyn paper mill in Pretoria, South Africa.

As part of this partnership, ABB will upgrade the automation system for Neopak’s Paper Machine 3 (PM3) using its state-of-the-art Ability System 800xA Distributed Control System (DCS).

The mill currently produces diverse paper products, including high-performance recycled liner, fluting, paper bags, core board, and plasterboard.

The upgrade integrates the latest technological advancements and aims to boost operational efficiency, productivity, and consistency through smart manufacturing practices.

PM3, operational for over 15 years, has recently increased its production capacity to approximately 85,000 tons annually.

The planned upgrade will allow Neopak to meet growing market demand by significantly improving production efficiency and product quality.

ABB’s enhanced DCS will integrate seamlessly with existing systems, including the ABB Quality Control System (QCS) and variable speed drives while introducing new features like advanced process control (APC) and enhanced cybersecurity.

This integration, through a centralised monitoring and control platform, is expected to reduce waste, improve yield, and streamline operations.

ABB has been tasked with designing a phased digital transformation strategy for Neopak. This roadmap includes implementing tailored digital solutions for the pulp and paper sector and prioritising advanced process control, cybersecurity, and operational accuracy.

The Ability System 800xA will also optimise production schedules, helping operators make informed decisions and respond quickly to process variations.

Transformational impact by 2025

The first stages of this digital transformation are set to commence in 2025, with commissioning expected in the third quarter of the year.

The improvements are anticipated to result in higher throughput, enhanced paper quality, and greater efficiency across the manufacturing process.

Neopak Operational Director Nitesh Singh praised ABB’s expertise and commitment to innovation, “ABB is a champion for the South African pulp and paper industry and a trusted partner in our business. Expanding our partnership with them is a natural step toward achieving our digitalisation goals.

“Their digital toolkit, combined with extensive industry expertise, is helping us unlock smart manufacturing at Neopak.”

ABB South Africa Pulp and Paper Account Manager Arvin Ramjee echoed this sentiment, “We are proud to support Neopak on its journey toward smart manufacturing.

“This project underscores ABB’s dedication to helping manufacturers globally achieve their digitalisation objectives and optimise operations for long-term success.”

This partnership sets a new benchmark for digital innovation in South Africa’s pulp and paper industry, positioning Neopak to lead in sustainable and smart manufacturing.

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