Paper with Purpose: Modernizing the Pulp and Paper Industry

The pulp and paper industry (PPI) is fundamental to daily life, producing paper and cardboard for everything from tissues to coffee filters to packaging. It produces more than 400 million tons (Mt) of paper per year¹ – a figure expected to reach 900 Mt by 2050. However, it is also one of the world’s most resource-intensive industries, consuming substantial amounts of energy and water. The PPI was responsible for just under 2% of all direct industrial emissions in 2022². As a champion of sustainable forest management and recycling, the sector does have a unique opportunity in the world’s transition to a circular economy and low-carbon society.

Pulp and paper industry footprint

As global demand for paper products rises, driven by increasing population and a shift from single-use plastics, the industry serves a market worth $357 billion. This is projected to grow at a compound annual rate of 3.8 percent from 2024 to 2028³, which brings both opportunities and challenges: manufacturers must find ways to improve productivity while reducing their environmental impact.

Overcoming Obstacles: The Path Forward for the Pulp and Paper Industry

Today’s pulp and paper industry is evolving, adapting to new consumer needs and innovative product possibilities, including paper-based alternatives for bags, bottles, and even battery components. But achieving this evolution sustainably requires overcoming significant challenges.

As the industry moves forward, these innovations will be critical in reducing emissions and ensuring that the pulp and paper sector can meet the world’s demands sustainably.

Automation and digitalization are crucial for a sustainable future

ABB has a rich history with the paper and pulp industry. Automation, digitalization and modern equipment are essential for the pulp and paper industry, can minimize resource consumption, reduce emissions and improve process efficiency. It is estimated that digitalization itself could save the pulp and paper industry $20 billion by 2025, raising productivity, reducing waste, and keeping mills safe. For more than 100 years, ABB has been at the forefront, helping companies navigate the challenges of increasing productivity while staying secure and energy efficient.

Some key ABB projects globally include:

Manufacturing operations

China
India
Sweden
Egypt
Morocco

The collaboration between FirstPak and ABB is transforming the sustainability of take-out packaging. Our partnership is helping to replace single-use plastics in the world’s largest takeout operations. By deploying 200 robots, FirstPak has doubled production line efficiency and cut energy costs by up to 30 percent, all while producing degradable, eco-friendly packaging.

Our Drive System enhances energy efficiency at UPM’s Changshu Paper Mill. Three months after the deployment of the new drive system in March 2024, data analysis revealed a 5 percent monthly reduction in power consumption for Rewinder II compared to the pre-upgrade period, leading to an expected annual cost saving of 450,000 yuan. 

ABB has collaborated with Parason, one of the largest manufacturers & suppliers of pulp and paper machinery to automate and up-scale production of sustainable and compostable packaging solutions. These molded fiber tableware products are widely used across multiple industries across restaurants and cafes, food catering, transport, travel and industry canteens.

Packaging giant Billerud in Karlsborg, northern Sweden, lives by the idea of renovating rather than replacing. So, a retrofit solution with new energy-efficient circuit breakers was a perfect match when its decades-old switchgear needed new life. With many components provided by ABB, including low and medium voltage switchgear, UPS, motors, drives and 800xA control systems, the plant is able to run leaner and cleaner.

The SCA Östrand pulp mill invested in a system simulator to train operators on its new recovery boiler that generates renewable electricity. From day one, the mill was able to deploy skilled operators to run the new recovery boiler, made possible by one full week of simulator training. This both lowered the risk potential and realized cost savings through the virtual training module.

In operation since 1999, Quena Paper is the largest writing and printing paper grade mill in the country which uses raw materials (bagasse) mostly made of sugarcane. IBy using our ACS880 multidrives and Paper Machine Drives PMC800 library we have modernized the mill's production processes with state-of-the-art automation and control capabilities.

Sipat S.A. produces high-quality facial tissues, toilet paper, napkins, and kitchen towels. ABB’s Quality Control System (QCS) for pulp and paper has now been integrated into the premium tissue mill in Morocco. The package of technologies will enhance plant performance, increase efficiency, and ensure long-term reliability on two modern machines.

Digital solutions

UK
Mexico
France
Spain

The DS Smith Kemsley paper mill in Kent is a century-old manufacturer of fiber-based packaging. ABB worked closely with this customer to map out the complex architecture to implement cyber security systems from automation to control to IT, allowing the mill to do more with digital safely and securely.

ABB secured a landmark contract to modernize Smurfit Kappa’s Paper Machine 5 (PM5) at its Cerro Gordo corrugated cardboard mill near Mexico City. Our ABB Ability™ System 800xA® distributed control system (DCS), accompanied by a comprehensive paper machine drives system, will optimize PM5’s performance.

ABB has been selected as a project partner for the installation of the world’s widest uncoated machine-glazed (MG) paper machine at Gascogne Papier’s kraft pulp and paper production plant in Mimizan, France. Our IE5 SynRM motors will help Gascogne Papier reduce energy losses and contribute to decarbonization goals.

The Papelera Brandia mill implemented ABB’s ABB Ability™ Energy Management System (EMS) which led to significant savings and emissions reductions. Total energy savings are €288,830 per annum, with a 9.9 percent reduction in electricity usage and a 7.9 percent reduction in natural gas usage. In addition every year, the initiative saves 1,467 tonnes of CO₂.

We invented the online quality control paper scanning technology that is now standard on all paper machines globally. Partnering with our customers using our electrification, automation and digitalization technologies, along with measurement and control products and applications, we make the pulp and paper industry run smoothly and become more energy efficient, productive and sustainable.

Footnotes

1. Decarbonizing the pulp and paper industry: A critical and systematic review of sociotechnical developments and policy options - ScienceDirect

2. Pulp & paper - IEA

3. The road less travelled in papermaking |Navigating known challenges when scaling operations - Pulp & Paper Industry Insights (Pulp and paper) | ABB

4. https://ketos.co/resources/pulp-and-paper-industry-fact-sheet