ABB upgrades automation, drive and quality systems at Holmen’s Iggesund Mill in Iggesund; production kept running through regular shutdowns

ABB upgrades automation, drive and quality systems at Holmen’s Iggesund Mill in Iggesund; production kept running through regular shutdowns

Future-proofed automation strengthens operations at Iggesund Mill | ABB

At Holmen’s board mill in Iggesund, industrial experience meets advanced technology. The paperboard machines are hundreds of meters long, operate around the clock and produce high-quality paperboard for applications including consumer packaging, customized premium packaging and medical packaging. Here, availability, quality and safety are critical – every day, all year round.

Step-by-step modernization with production in focus In recent years, ABB and Iggesund Mill have worked together in a multi-year modernization program. The project has been carried out step-by-step during regular maintenance shutdowns to minimize the impact on ongoing production. At the center has been a carefully developed migration and time plan, with each stage planned to meet high requirements for safety, quality, time and budget. ABB’s work has covered upgrades and migrations across the automation, drive and quality systems. The legacy AC450 platform has been replaced with AC800 and new application code in Function Designer. In the drive systems, ACS600 and ACV700 solutions have been upgraded to ACS880 with the new PMC800 application library. The quality system has also been modernized, moving from AC450 and SP1200 measurement frames to AC800 and NP1200, and adding the latest-generation HPIR-T moisture sensor. By combining new technology with reuse of existing OT infrastructure, the modernization has been carried out with low risk and high continuity. For the Iggesund Mill, it has been about strengthening an already advanced production environment without compromising operational reliability or quality. “For us, it has been crucial to modernize in controlled steps while keeping production running. Through clear planning and close collaboration with ABB, we have been able to carry out extensive upgrades during regular shutdowns, with a focus on safety, quality and long-term operational stability,” says Mikael Larsson, Project Manager, Iggesund Mill.

Step-by-step modernization with production in focus

In recent years, ABB and Iggesund Mill have worked together in a multi-year modernization program. The project has been carried out step-by-step during regular maintenance shutdowns to minimize the impact on ongoing production. At the center has been a carefully developed migration and time plan, with each stage planned to meet high requirements for safety, quality, time and budget.

ABB’s work has covered upgrades and migrations across the automation, drive and quality systems. The legacy AC450 platform has been replaced with AC800 and new application code in Function Designer. In the drive systems, ACS600 and ACV700 solutions have been upgraded to ACS880 with the new PMC800 application library. The quality system has also been modernized, moving from AC450 and SP1200 measurement frames to AC800 and NP1200, and adding the latest-generation HPIR-T moisture sensor.

By combining new technology with reuse of existing OT infrastructure, the modernization has been carried out with low risk and high continuity. For the Iggesund Mill, it has been about strengthening an already advanced production environment without compromising operational reliability or quality.

“For us, it has been crucial to modernize in controlled steps while keeping production running. Through clear planning and close collaboration with ABB, we have been able to carry out extensive upgrades during regular shutdowns, with a focus on safety, quality and long-term operational stability,” says Mikael Larsson, Project Manager, Iggesund Mill.

Future-proofing through reuse and continuity A central part of the project has been to create a future-proof technology platform without unnecessarily dismantling investments that are still working well. Through the migration from AC450 to AC800, Iggesund Mill has gained a more modern automation environment with improved opportunities for further development, while parts of the existing infrastructure have been retained. In the same way, the transition to ACS880 within the drive systems and the modernization of the quality system have contributed to a more consistent, user-friendly environment that is easier to maintain over the long term. The modernization also includes functions that strengthen daily operations, such as improved fault diagnostics, more modern start-warning systems and increased operator safety. This provides better conditions for faster troubleshooting, clearer operator support and more robust production over time. “The excellent collaboration and shared understanding of common goals, together with Iggesund’s strong project management and experience of complex industrial projects, have been important success factors. The well-developed migration and time plan has meant that our employees have experienced the implementation very positively,” says Mikael Lundgren, Key Account Manager at ABB.

Future-proofing through reuse and continuity

A central part of the project has been to create a future-proof technology platform without unnecessarily dismantling investments that are still working well. Through the migration from AC450 to AC800, Iggesund Mill has gained a more modern automation environment with improved opportunities for further development, while parts of the existing infrastructure have been retained. In the same way, the transition to ACS880 within the drive systems and the modernization of the quality system have contributed to a more consistent, user-friendly environment that is easier to maintain over the long term.

The modernization also includes functions that strengthen daily operations, such as improved fault diagnostics, more modern start-warning systems and increased operator safety. This provides better conditions for faster troubleshooting, clearer operator support and more robust production over time.

“The excellent collaboration and shared understanding of common goals, together with Iggesund’s strong project management and experience of complex industrial projects, have been important success factors. The well-developed migration and time plan has meant that our employees have experienced the implementation very positively,” says Mikael Lundgren, Key Account Manager at ABB.

More stable operations and a safer path forward The result is a modernized mill environment that provides better conditions for high availability, stable operations and continued efficiency improvements. The step-by-step migration model has reduced implementation risk and made it possible to keep focus on ongoing production while the mill continues to build toward future requirements. For ABB, the project shows how industrial modernization can be carried out with both continuity and forward momentum. By combining local expertise in sales, project execution and service with deep knowledge of pulp and paper industry processes, ABB has been able to contribute to a solution that is adapted to the reality of Iggesund Mill and ready for the next step. “The technology migration gives us a stronger platform for continuing to develop the mill. It contributes to increased robustness in operations and makes it easier to meet future requirements for availability, quality and safety,” says Mikael Larsson.

More stable operations and a safer path forward

The result is a modernized mill environment that provides better conditions for high availability, stable operations and continued efficiency improvements. The step-by-step migration model has reduced implementation risk and made it possible to keep focus on ongoing production while the mill continues to build toward future requirements.

For ABB, the project shows how industrial modernization can be carried out with both continuity and forward momentum. By combining local expertise in sales, project execution and service with deep knowledge of pulp and paper industry processes, ABB has been able to contribute to a solution that is adapted to the reality of Iggesund Mill and ready for the next step.

“The technology migration gives us a stronger platform for continuing to develop the mill. It contributes to increased robustness in operations and makes it easier to meet future requirements for availability, quality and safety,” says Mikael Larsson.

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