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Client: Leading Global Hygiene & Health Company
Client Type: End user
Industry: Pulp & Paper
Location: UK
Scope: Full paper machine drive and control system retrofit and safety upgrade
Improved reliability and uptime through modernised drive and control architecture
Obsolescence risks removed by replacing outdated ABB and Rockwell systems
Enhanced operator safety to EN13849, PL ‘d’, Cat 3 with Safe Torque Off (STO)
Future-ready infrastructure designed for scalability and digital monitoring
Minimal production disruption thanks to phased installation planning
A leading global hygiene and health manufacturer faced a critical challenge in upgrading its ageing paper machine drive systems at one of its pulp and paper mills.
The site’s existing ABB ACS600 drives and Allen-Bradley PLC5 control system had become obsolete, resulting in increased maintenance effort, limited spares availability and reduced reliability.
The client sought a comprehensive modernisation to improve output, reduce harmonic distortion through active front-end drive technology, and significantly enhance operator safety.
In addition, the project had to be executed without major disruption to production. Careful coordination was required during installation and commissioning to ensure continuity of mill operations while achieving compliance with current machine safety standards.
Leveraging our extensive experience in obsolescence upgrades, machine safety and multi-vendor automation integration, iconsys was selected to deliver a turnkey retrofit solution.
Our scope covered the complete modernisation of the paper machine’s drive and control systems, focusing on reliability, flexibility, and long-term compliance.
Drive System Upgrade
The obsolete ABB ACS600 drives were replaced with high-performance ABB ACS880 modules installed in a new drive suite. This retrofit approach enabled reuse of existing infrastructure such as power cabling, control wiring and ventilation, reducing both project costs and installation time. The new low-harmonic front-end modules ensured compliance with the latest energy efficiency and grid regulations.
Controller Modernisation
The legacy ABB AC80 controllers were replaced with modern Rockwell ControlLogix PLCs, providing faster processing, enhanced diagnostics and improved scalability for future plant developments. A new drive network was designed and commissioned, with all drives interconnected and monitored through ABB Drive Composer Pro software for real-time control and optimisation.
Network Integration & Monitoring
A new remote monitoring gateway (EWON) was implemented, enabling secure off-site access for system updates and troubleshooting. This enhanced operational visibility and minimised downtime by allowing proactive maintenance without production interruption.
Safety & Compliance Integration
Safety compliance was a cornerstone of the project. The upgraded system achieved EN13849 Performance Level ‘d’, Category 3 with integrated Safe Torque Off (STO) functionality, validated through SISTEMA calculations.
A GuardLogix safety PLC with remote safety I/O provided a robust safety architecture, and—significantly—this project marked the first implementation in Europe of a CIP Safety over Ethernet/IP protocol between Rockwell PLCs and ABB drives, setting a new benchmark for machine safety in the paper industry.
The entire system was CE marked in accordance with EN60204 (Machinery Directive) requirements.
Installation & Commissioning
Working closely with the client’s operations team, iconsys developed a detailed, phased installation strategy. This plan allowed production to continue during key stages of the upgrade, avoiding multiple full shutdowns. Pre-shutdown preparation and flexible scheduling were critical to ensuring a smooth, efficient transition.
The upgraded system has delivered measurable reliability and safety improvements across the paper machine line. The transition to ABB ACS880 drives and Rockwell ControlLogix PLCs has provided faster, more stable control, reduced harmonic distortion, and lower maintenance demands.
By eliminating obsolete hardware and introducing remote diagnostic access, the client now benefits from higher uptime, simplified support, and improved operational visibility.
Safety enhancements validated to EN13849 PL ‘d’, Cat 3 have significantly reduced risk to operators and ensured full compliance with the latest EU Machinery Directive.
The flexible system architecture and low-harmonic design have future-proofed the mill’s automation infrastructure, supporting future capacity expansions and digital transformation initiatives.
The client selected iconsys for its proven track record in complex obsolescence upgrades, machine safety compliance, and multi-vendor integration expertise. Our end-to-end project management, from design through commissioning, ensured the solution met stringent performance, safety and reliability requirements without disrupting production.
This successful project reinforces iconsys’s position as a trusted automation partner to global manufacturers, capable of delivering future-ready solutions that combine innovation, compliance and operational excellence.
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