Saica is a family owned company and market leader in southern Europe in the manufacturing of corrugated paper. The company has a total production capacity of over 2 million tons a year, and is focused on quality, sustainability, safety and innovation. ABB's delivery will help Saica's new mill operate at top efficiency while maintaining high product quality. Saica chose ABB for this project after a successful installation of the same technology on its PM10 production line.
ABB's PMC800 Direct Drive solution will reduce overall equipment investment costs by eliminating gear boxes, encoders, primary couplings, gear lubrication. ABB's unique Direct Torque Control (DTC), combined with AC800 drives control system, enable encoderless motor control and operation in Paper Machines.
In addition to eleminating the external gears boxes, the highly efficient Direct Drive solution provides energy savings throughout the system lifecycle. Its16 installed permanent magnet motors are mostly located at the dryer, representing less than 20% of the total drive power. Dryer section electrical energy losses are 17% lower than that of a traditional drive system, with estimated energy savings over 20 years projected at more than $400,000. ABB's solution requires less maintenance and minimizes downtime, as well as reduces initial construction costs, resulting in lower overall system lifetime costs.
The new paper machine PM11 will be ready for start-up in January 2012.