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Rolling, rolling, rolling! Aluminum plant in continuous operation

Long-term, tailored service contract guarantees telephone support around the clock and ABB remote access to the 800xA system

At the Nachterstedt site, Novelis Deutschland GmbH produces high-quality rolled aluminum products to the automotive, can, industrial and building markets worldwide. For two decades now, the Novelis and ABB have been working together on the electrical and automation-related equipment of the aluminum rolling mill. In multiple steps, ABB modernized the automation system during ongoing production. Most recently, Novelis also signed a long-term, tailored service contract that guarantees telephone support around the clock and ABB remote access to the 800xA system.


For companies, non-operating manufacturing facilities result in production outages and financial losses. When it comes to maintenance or modernization activities, the primary objective is to avoid plant downtimes entirely or keep them as short as possible. This requirement also applies for Novelis Deutschland GmbH at their site in Nachterstedt, Saxony-Anhalt, Germany. The company is linked to ABB through a partnership dating back many years. 

The first order, in 1994, involved installing all the electrical equipment for the newly constructed automotive annealing and painting line as well as for a slitting line. The main challenge at that time was in the scope of the services provided, which ranged from the medium-voltage feed to installing an Advant Master control system with 18 MP200 RMC controllers, and even to all the drives for the production line.

Modernization in multiple steps

The step-by-step modernization of the automation system began in 2000. Among other things, the original controllers were replaced with newer from the Advant range. Controllers of the type AC450 RMC gradually replaced the 18 old MP200 RMC controllers. In 2008, ABB was awarded a contract to electrically equip the Can End Stock (CES) plant, commission it and integrate it into the annealing and painting line. The 800xA control system replaced the former Advant system and enabled the existing MP200 and AC450 RMC controllers of the annealing and lacquering system to be retained without any changes and the CES to be equipped with eight AC 800 PEC high-performance controllers and 79 ACS800 frequency converters.

The 800xA control system replaced the former Advant system and enabled the existing MP200 and AC450 RMC controllers of the annealing and lacquering system to be retained without any changes

Comprehensive service

Only regular modernization of manufacturing facilities keeps productivity and quality permanently at the highest level. It is therefore self-evident for ABB to not only install efficient automation technology, but also retain an overview of a production plant throughout its entire lifecycle. Last year, the two partners signed a long-term, tailored service contract that guarantees Novelis telephone support around the clock and ABB remote access to the 800xA system. This means that service specialists can resolve failures within the shortest time from the site in Ratingen and do not have to actually be present in Nachterstedt. As part of the lifecycle strategy, Novelis is also always informed in good time when and which products will no longer be manufactured and when the supply of replacement parts will end. With this combination of specialist expertise and an extensive service offering, ABB ensures the availability of the automation and drive technology at Novelis.

With telephone support around the clock and remote access to the 800xA system ABB service specialists can resolve failures within the shortest time from the site in Ratingen and do not have to actually be present in Nachterstedt

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