ABB supports Model Sachsen Papier in groundbreaking transformation

For over 30 years, paper has been produced in Eilenburg—primarily for the newspaper industry and commercial printing. However, as demand for graphic paper declines and the need for packaging materials grows, Model Sachsen Papier took a forward-thinking step and reoriented itself: the paper mill converted its entire production to corrugated base paper for the packaging industry. 

Model Sachsen

For this ambitious project, the company relied on its long-term partnership and ABB’s specialized expertise. Within 14 months, the entire plant was revamped and equipped with one of the most advanced paper machines worldwide. This collaboration demonstrates how industrial sites can be made future-ready through innovative technologies and strong partnerships.

With the start of the paper mill's conversion in the summer of 2023, an era came to an end on Schanzberg in Eilenburg. Since 1994, the paper machine there had been producing paper for newspapers, flyers, and advertising materials. But times are changing, and so is market demand. In 2021, the Swiss Model Holding AG acquired the plant with the goal of fully transitioning production to corrugated base papers, which are also processed further at Model locations in Poland, Czechia, and Germany. The acquisition marked the beginning of a comprehensive transformation process for the plant under the name "NIKE"—named after the Greek goddess of victory.



Published April 2025.

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ABB chosen as a key partner for modernization of the Eilenburg Paper Mill

This strategic move required a complete overhaul of the existing facilities. As a long-standing partner of the Eilenburg paper mill, ABB was involved from the very beginning. Our teams contributed their technical expertise, solution competence, and extensive industry knowledge to the project. The challenge for all involved was enormous: the entire plant needed to be rebuilt, from wastewater treatment and pulp preparation to the core of the factory—the paper machine itself.

 “Since the establishment of the site, ABB has been our reliable partner in motor and drive technology. So, it was obvious for us to continue this cooperation during the conversion of our plant,” shared Martin Kaltenegger, Project Manager, Model Sachsen Papier.

 

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Paul Joly, Account Manager Pulp & Paper at ABB and Dirk Schwarze, Managing Director of Model Sachsen Papier, affirm the successful collaboration

Innovative multi-motor concept for increased performance with existing infrastructure

A particular focus during the mill’s conversion was sustainability: the existing components of the paper machine were to be reused as much as possible. This requirement posed a multidimensional puzzle, which our experts skilfully solved. While a large part of the existing components continues to be used in the rebuilt paper machine, ABB achieved a performance increase of 25% —despite using the same number of transformers and supply units and without expanding the switchgear room.

To achieve this, ABB implemented an innovative multi-motor concept for process drives, minimizing the need for re-cabling for the power section, bus communication, and auxiliary power supply. This solution proved especially valuable given the limited space in the existing switchgear rooms, optimizing their use. Additionally, ABB provided drives for new roll cutters and the first medium-voltage drives for the two pulper drums, with the order volume for ABB reaching double-digit millions.

“A conversion of this magnitude involves many risks, but on the motor and drive side, we were not disappointed. The excellent teamwork with the committed and competent project and commissioning team ensured a smooth start-up within ABB’s area of responsibility,” said Dirk Schwarze, Managing Director, Model Sachsen Papier. 

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Since the modernization, Model Sachsen Papier in Eilenburg can produce more than 600,000 tons of paper per year – and with one of the most modern paper machines in the world. Photo: Model Sachsen Papier.

Pilot project with ABB Paper Machine Drives Performance

A highlight of the transformation was the installation of an innovative digital solution. ABB implemented the new Paper Machine Drives Performance system for paper machine drives as a pilot project. This technology enables real-time monitoring and analysis of the paper machine’s drive performance. By using advanced analytics and a user-friendly interface, Model Sachsen Papier can now optimize the machine’s efficiency, minimize downtime, and carry out predictive maintenance.

The comprehensive overhaul of the Eilenburg paper mill was completed in 14 months. On September 3, 2024, at 8:14 p.m., the first corrugated board base paper was rolled onto the drum—a milestone for Model Sachsen Papier. At full capacity, the plant now produces over 600,000 tons of paper annually, made entirely from recycled paper, enabling their commitment to sustainable operations.

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With the successful transformation of the paper factory in Eilenburg, Model Sachsen Papier is taking a big step towards sustainable paper production. Photo: Model Sachsen Papier.

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