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Freelance: Pulp and paper mill attains improved efficiencies and product quality

As with almost every industry, the pulp and paper industry too has its own challenges. High competition, decreasing margins, the need for specialized and skilled manpower, high energy costs and high down time periods are challenges typical of the industry.


I needed a solution that must assure signals accuracy, minimizing process variability. -- Luiz Cesar Freitas Production Manager, Sao Gabriel Papeis


Sao Gabriel Papeis, a pulp and paper company located in União da Vitória, Brazil, is a small company with many competitors. Without spending a lot of money to improve the productivity, they needed to implement entry level solutions that could optimize costs and improve the availability of the paper machines. With a small investment in an ABB solution which was commissioned in January 2012, they were able to achieve their goals.

The main problem was that the paper machine had a long down time due to the paper breaks. With ABB Freelance, the DCS for process industries, this problem can be better understood and mitigated in the near future.

Sao Gabriel Papeis was looking for a system integrator that was able to provide a package that could improve production quality.

I needed a solution that must assure signals accuracy, minimizing process variability.
-- Luiz Cesar Freitas
Production Manager, Sao Gabriel Papeis


They are now so confident with the Freelance solution that they want to expand the initial system to the boiler which is currently controlled by a PLC.

About Plus Engenharia Eletrica e Automacao Industrial

Plus Engenharia Eletrica e Automacao Industrial has extensive experience in PLCs with many applications installed in the south and southeast of Brazil. Their services include electric power consulting, electrical projects for low, medium and high voltage and sale of electrical components. They are specialists in thermography is a technique that extends the human vision through the infrared spectrum, which now has a very important role in the area of predictive maintenance. Its use can eliminate many production problems, avoid electrical, mechanical and material fatigue.

In order to maintain peak performance of equipment involved in the industrial process, the use of thermography in predictive maintenance program is essential. Examples of thermographic inspection in industrial processes are: verification of refractories in furnaces, measurement of temperature variation on roll paper, rolling mills, dryers, plastic machinery, amongst others.

Benefits

The ABB Freelance solution proved to be a very innovative and reliable system used to control the mixing pump and that has reduced the number of paper breaks in the paper machine, thereby generating savings and profitability for Sao Gabrieis Papeis. They are now so confident with the Freelance solution that they want to expand the initial system to the boiler which is currently controlled by a PLC.

ABB’s Supply

The system comprised of the Freelance Starter Kit (Combi Station + AC 700F + DC 732F + AX 722F), with additional hardware (1 Profibus DP card CM 722F, 1 additional AX 722F and 1 additional DC 732F).

The system also included a ACS550 driver in Profibus, DP, a multimeter IDM96 in Modbus RTU and a pressure transmitter 266 HSH in 4-20 mA.
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