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Automation systems and hardware upgrades for the largest renewable packaging facility in Pakistan

ABB has successfully implemented the first distributed control system in Pakistan - ABB Ability™ System 800xA - as part of an upgrade at Bulleh Shah Packaging (Pvt) Limited.

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ABB Ability System 800xA enables improved control and remote monitoring of paper machines, power house, coater machines and stock areas and provides management with dashboards for quick plant overviews. Being a first of its kind virtualized solution in Pakistan, it increases energy efficiency, reduces hardware costs and work space thanks to the minimized dependencies on hardware.

Market leader in corrugated packaging

Bulleh Shah Packaging (Pvt.) Limited, a Packages Group Company, is the market leader in corrugated packaging, the largest renewable packaging facility and the only liquid packaging board providing facility in Pakistan.

The packing company was facing challenges with their previous automation systems and hardware, and they were running into bottlenecks in their day-to-day production activities. “The customer complained about the slow performance of their system, overloading of field controllers and difficulties in handling the 16 server machines and 25 operator stations. The outdated hardware and server room environment was badly affecting the hardware of the servers and operating stations,” said Zeeshan Ullah Chaudhary, Project Manager, ABB. 

Main facts

Industry Pulp and Paper
Customer Bulleh Shah Packaging
Country Pakistan
Solutions

ABB Ability System 800xA with

comprising 29 field controllers, 1,900 graphical aspects and over 20,000 tags
Year
 2018

Dramatic improvement in remotely monitored KPIs

There was a high expectation from customer’s side as they were keen to see a dramatic improvement in their key performance indicators (KPIs), which are remotely monitored.

ABB’s solution to this problem was to introduce an 800xA Smart Client solution for plant management, to view and develop different dashboards for quick plant overviews and also conduct management trainings, so managers can develop their own dashboards.

Minimized dependencies on hardware

ABB also pitched the idea of virtualizing with standby fall-over server and SAN storage server. The virtual machine technology replaced 16 redundant physical hardware units with two virtual servers and 25 workstations. 

Being a first of its kind virtualized solution in Pakistan, it is a step forward for ABB in the country. The virtual solution has helped the customer make sweeping changes such as increased energy efficiency, reduction in hardware costs and work space thanks to the minimized dependencies on hardware.


Swift upgrade by the local ABB team within 48 hours

“This example became the first one where the customer put their trust on the local ABB unit for such a large upgrade project. They trusted our competency and skillfulness and we were able to meet the biggest challenge of installation; testing and upgrade of two paper machines, one coater machine and a 41 MW power plant within 48 hours,” added Zeeshan.


The upgrade involved paper machines, power house, coater machines and stock areas adding up to a total business of 800,000 USD in value. This project strengthens ABB’s position in the paper industry.


"We are a continuous process industry with Pakistan’s biggest DCS control network comprising of 29 field controllers, 1,900 graphical aspects and over 20,000 tags. What we required at the time of upgrade was a team that could upgrade our swiftly aging system with the latest solution providing 100% reliability " said Jahanzeb Khan, Technical Manager at BSPL Paper & Board.


Jahanzeb Khan, Technical Manager, BSPL Paper & Board.
“Our first inclination was towards ABB Italy, who were our main system implementation team, but ABB in Pakistan ensured and guaranteed us of their technical competence and professionalism for implementing this massive upgrade. They eventually did, meeting the tough timelines provided to them for completion of this upgrade”

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