ABB has won a significant contract to modernise Smurfit Kappa’s Paper Machine 5 (PM5) at its Cerro Gordo corrugated cardboard facility near Mexico City. ABB will provide Smurfit Kappa with its ABB Ability™ System 800xA® distributed control system (DCS) and a comprehensive paper machine drives system. The system includes some of the market’s most modern drives and motors precisely tailored to optimise PM5’s performance.
Smurfit Kappa is one of the leading providers of paper-based packaging globally, with operations spanning across 35 countries. It has operated in Mexico since 1957 and has been increasing production capacity in the country recently, investing over USD 350 million since 2018.
The modernization of the machines in the Latin American pulp and paper industry
The project marks the first collaboration between the two parties in this region and signals a new era of operational efficiency for one of the packaging producer’s busiest machines in Mexico. The modernization is expected to transform PM5 into a highly efficient and productive machine, capable of meeting the demands placed on it. Upon completion of the project, Smurfit Kappa is expected to realize a significant increase in production efficiency and output.
Smurfit Kappa sought a partner with unparalleled expertise to spearhead this critical modernization project. Smurfit Kappa required speed and tension controls to operate at optimum levels, while keeping downtime to a minimum. ABB, with its proven track record in the Latin American pulp and paper industry and deep understanding of paper machine processes, emerged as the ideal choice.
The optimal speed and torque control of the paper machine’s sectional drives
The ABB technology embedded in the drives, complemented by the control system, will help secure optimum speed and torque control of the paper machine’s sectional drives for years to come. This is achieved through a combination of factors such as a Direct Torque Control algorithm, which ensures precise control and allows for consistent quality and minimized waste over a long period of time. ABB guarantees a system uptime of 98.5 percent during a three-month period following the machine’s startup in 2025. This translates to a maximum downtime of only 33 hours within that timeframe.
“We are impressed by ABB’s deep understanding of the industry and their commitment to exceeding expectations,” said Mario Olvera, Engineering and Project Director, Smurfit Kappa Mexico. “We are confident that their expertise will be instrumental in maximizing the performance and efficiency of PM5. This project represents a significant step forward for Smurfit Kappa in Mexico, and we look forward to a successful collaboration with ABB.”
“Partnering with Smurfit Kappa on this momentous project will help ensure optimal equipment design, control performance, and seamless commissioning,” said Diego Navas, Regional Sales Manager, ABB Pulp and Paper, North America. “A dedicated team of ABB specialists will work alongside our customer on the machine to deliver significant benefits, including increased production, improved efficiency, and reduced operational costs.”
The project’s scope extends beyond simply supplying equipment. ABB will leverage its extensive experience to provide comprehensive engineering and commissioning services, ensuring a smooth transition to the upgraded PM5. Backed by its ABB Ability™ System 800xA® and Remote Access Platform, ABB can provide customer support from anywhere in the world at any time. The safety functions and process panels installed alongside the machine will allow collaborative, easy and safe operation of the machine.
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 customers in process, hybrid and maritime industries improve performance and safety of operations, enabling a more sustainable and resource-efficient future. go.abb/processautomation
ABB is a technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. The company’s solutions connect engineering know-how and software to optimize how things are manufactured, moved, powered and operated. Building on over 140 years of excellence, ABB’s more than 105,000 employees are committed to driving innovations that accelerate industrial transformation.www.abb.com
(2/2) ABB will support the modernization of systems for the board producer’s PM5 (photo: Smurfit Kappa)
(1/2) The Cerro Gordo mill has benefited from investment to increase production capacity. (photo: Smurfit Kappa)
