DS Smith aims to improve automation with new ABB contract

DS Smith, a paper packaging producer based in the United Kingdom, has announced a new contract with Swedish technology company ABB to futureproof operations and strengthen cybersecurity functionality at its Kemsley Mill in the U.K.

The paper mill, located in Kent in South East England, is the largest mill for recycled paper in the U.K. and second largest in Europe with an annual production capacity of approximately 840,000 tons, producing light medium which DS Smith says is the first recycled lightweight paper manufactured in the U.K.

In a news release announcing the contract, ABB says it is supporting Kemsley Mill's evolution with the ABB Ability System 800xA distributed control system (DCS) and paper machine drives upgrade across the PM3, PM4 and PM6 machines. According to ABB, the upgraded DCS will be integrated across the mill to work as the backbone that connects everything securely in one system for more automated functionality and easier maintenance.

"ABB's consultation, involving numerous remote workshops and ongoing discussions, helped us define the best approach for our modernization project," Kemsley Mill Manager Ben Jennings says. "The team showed real expertise and understanding of our future ambitions and will act as a partner to us in our digital transformation journey."

ABB also will provide a one-year support contract, the latest cybersecurity set-up and new two virtual measurements for PM4, which will provide online calculations for strength and weight. The system is expected to be delivered in the third quarter of this year and DS Smith says a "progressive implementation of the system will align with the planned maintenance program in the successive months."

"DS Smith is a leading European and U.S. paper manufacturer with a clear vision for their future operations," says Jan-Willem Bos, regional industry lead, ABB Pulp and Paper. "The Kemsley Mill is a great example of a facility with the foresight to plan for the bigger digitalization rapidly emerging in the pulp and paper industry. We're please to build on our longstanding relationship and work closely with DS Smith to drive their strategic evolution."

DS Smith has made several investments in the past several years into automation and technology at the Kemsley Mill. In August of last year, the company invested in 10 automated guided vehicles (AGVs) to increase sustainability and efficiency. The all-electric Rocla vehicles supplied by Mitsubishi Logisnext Europe Oy, headquartered in Amsterdam, perform a variety of tasks around the warehouse, including collecting reels from the production conveyor, storing reels and picking reels for orders. When the AGVs aren't tasked with work, they automatically switch to housekeeping mode, rotating stocks in order of age and consolidating stocks to maximize warehouse capacity.

Jennings said last year, "The recent boom in e-commerce has increased the demand for our papers and packaging. Every day, around 2,400 tons of paper leaves the Kemsley Mill and so it's critical that our talented team has the latest innovations to benefit our people, customers and the environment."

In a recent trading update issued to investors, DS Smith Group Chief Executive Miles Roberts said the company expects up to $768 million in adjusted operating profits for its fiscal year, which ended in April. He cited "continued momentum [with] good progress in profitability and cash generation" during the previous six months.