The Maryvale Mill has been a cornerstone of Australian paper manufacturing since 1937 and has been using ABB automation systems for decades.
As part of its ongoing automation lifecycle strategy, Opal Australian Paper undertook an upgrade of its ABB Ability™ System 800xA distributed control system to the latest commercially available version. With the Maryvale Mill operating as a critical part of Opal's manufacturing network, the upgrade required detailed planning and close coordination to align with a tightly managed shutdown schedule and minimise disruption to operations.
Drawing on its long-standing relationship with Opal and extensive knowledge of the site's automation systems, ABB Australia delivered a complete upgrade of the ABB Ability™ System 800xA platform from version 5.1 FP4/E to the latest commercially available release. The project was executed in just eight weeks and completed during a five-day shutdown.
The scope of work included a full system version upgrade across the ABB Ability™ System 800xA platform, encompassing operating system upgrades across the site’s automation infrastructure, including servers, client workstations, storage systems and network equipment. The project also included firmware upgrades for controllers and communication devices, ensuring full system compatibility, stability, and performance across the upgraded architecture.
A key enabler of the project was Opal's Automation Software Maintenance (ASM) Agreement with ABB. The subscription-based ASM program provided access to the latest software version and ongoing software lifecycle support, helping streamline the upgrade process and supporting Opal's long-term automation roadmap.
By moving to the latest version of ABB Ability™ System 800xA, Opal established a modern automation environment that provides access to enhanced communication capabilities, continued software support and future digital applications available within the ABB ecosystem. The upgrade also created a strong foundation for ongoing technology development and operational improvement initiatives across the site.
The success of this project reflects what's possible when strong collaboration, local expertise and a shared commitment to continuous improvement come together." says Brad Burton, Pulp and Paper Industry Lead at ABB Australia. We're extremely proud to support Opal Australian Paper on its automation journey and to have delivered a complex mill-wide upgrade within a tightly managed timeframe. Together, we have established a platform that supports the site's ongoing operational requirements while providing a foundation for future technology initiatives.
