ABB lands modernisation project for Mexico board mill

ABB secured a landmark contract to modernise Smurfit Kappa’s corrugated cardboard mill near Mexico City. It will provide control system technology, drives, and motors, as well as ongoing expert service.

Smurfit Kappa is one of the leading providers of paper-based packaging globally, with operations in 35 countries. It has operated in Mexico since 1957 and has recently increased production capacity in the country, investing over USD350 million since 2018.

The project marks the first collaboration between the two parties in this region. It signals a new era of operational efficiency for one of the packaging producer’s busiest machines in Mexico. Modernisation is expected to transform Smurfit Kappa’s Paper Machine 5 (PM5) into a highly efficient and productive machine capable of meeting its demands. Upon completion of the project, Smurfit Kappa is expected to increase production efficiency and output significantly.

Smurfit Kappa sought a partner with unparalleled expertise to spearhead this critical modernisation project. They required speed and tension controls to operate at optimum levels while minimising downtime. With its proven track record in the Latin American pulp and paper industry and deep understanding of paper machine processes, ABB emerged as the ideal choice.

ABB will provide Smurfit Kappa with its ABB Ability System 800xA distributed control system (DCS), accompanied by a comprehensive paper machine drives system, encompassing some of the market’s most advanced drives and motors meticulously designed to optimise PM5’s performance.

The ABB technology embedded in the drives, complemented by the control system, will help secure optimum speed and torque control of the paper machine’s sectional drives for years to come. This is achieved through a combination of factors, such as a Direct Torque Control algorithm, which ensures precise control and allows for consistent quality and minimised waste over a long period.

ABB guarantees a system uptime of 98.5% for three months following the machine’s startup in 2025. This translates to a maximum downtime of only 33 hours within that timeframe.

“We are impressed by ABB’s deep understanding of the industry and their commitment to exceeding expectations,” said Mario Olvera, Engineering and Project Director, Smurfit Kappa Mexico. “We are confident that their expertise will be instrumental in maximising the performance and efficiency of PM5. This project represents a significant step forward for Smurfit Kappa in Mexico, and we look forward to a successful collaboration with ABB.”

“Partnering with Smurfit Kappa on this momentous project will help ensure optimal equipment design, control performance, and seamless commissioning,” said Diego Navas, Regional Sales Manager, ABB Pulp and Paper, North America. “A dedicated team of ABB specialists will work alongside our customer on the machine to deliver significant benefits, including increased production, improved efficiency, and reduced operational costs.”

The project’s scope extends beyond simply supplying equipment. ABB will leverage its extensive experience to provide comprehensive engineering and commissioning services, ensuring a smooth transition to the upgraded PM5. Backed by its ABB Ability System 800xA and Remote Access Platform, ABB can provide customer support anytime, anywhere in the world. The safety functions and process panels installed alongside the machine will allow the machine to operate collaboratively, easily, and safely.