DS Smith's Kemsley Mill: A Model for Secure Operations and Enhanced Connectivity in a Digital Age

Source: ABB

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The global pulp and paper industry is undergoing significant transformation as it embraces digitalization and adopts new technologies

However, as mills increase their connectivity levels, the risk of cyber vulnerabilities rises with it. A cyber breach in a mill can be devastating, leading to substantial financial and operational consequences, halting production, creating regulatory challenges, and disrupting customer trust. The collaboration between ABB and DS Smith at its Kemsley paper mill demonstrates how to address these cyber risks through embracing digitalization.

Addressing a generational challenge at Kemsley mill

DS Smith, a leader in sustainable fiber-based packaging, operates Europe’s second-largest recycled paper mill, the Kemsley mill in Kent, UK. As the mill approached its 100th anniversary, its team faced the challenge of modernizing operations with enhanced security. Though having relied on an older version of ABB Ability™ System 800xA distributed control system (DCS) successfully, DS Smith recognized the need for a system upgrade with enhanced cyber security architecture to support new technologies and take operations to the next level.

The goal was clear: enhance the mill’s cyber resilience while automating processes and improving connectivity. ABB’s demonstrated expertise and long-standing relationship with the mill meant that ABB was the natural choice for execution.

abb 30oct24 1DS Smith Kemsley Mill

Navigating the complexities of a large-scale upgrade

The DCS at Kemsley controls critical areas across the mill, which spans 1.1 square kilometers and is embedded in three paper machines. Collaborating over an 18-month period, ABB and DS Smith developed a tailored solution to meet the mill’s needs, focusing on architecture design, cyber security, and process efficiency. The project required careful planning and testing to ensure a smooth transition and mitigate disruptions to the mill's operations.

The upgrade was scheduled in phases, beginning with two paper machines (PM3 and PM4) and followed by PM6, alongside upgrades to the effluent and freshwater plant. This coordinated approach was crucial to minimizing downtime while ensuring the mill’s continued operations. The scale and complexity of the project was unprecedented, taking over 6,000 hours in advance and 12 days on site, making it one of the largest system upgrades ABB has supplied into the industry.

Combining cybersecurity with automation

At the heart of the upgrade was the upgrade of the ABB Ability System 800xA, which included a full upgrade of the integrated system, DCS, quality control system (QCS), and paper machine drives and associated control system IT infrastructure. The integration of virtual measurements for strength and weight enabled more accurate monitoring, increasing efficiency across the mill. However, cybersecurity was a core focus, with secure architecture embedded throughout the project, from IT to control to automation systems.

The successful execution of this upgrade required more than just technology. ABB’s close collaboration with DS Smith’s local teams and coordination with their Europe Regional Execution Center (EUREC) played a critical role in achieving smooth communication and effective project management.

A roadmap for the future

DS Smith’s Kemsley mill now benefits from enhanced visibility across its operations, thanks to ABB’s advanced cybersecurity and digitalization solutions. The system upgrade has positioned the mill for future advancements, providing a foundation for continued digital transformation.

Lessons for the Industry

For other companies in the pulp and paper industry at the beginning of their cybersecurity journey, ABB recommends a holistic approach. This involves a focus on people, policies, and procedures, supported by robust technology. A layered defense strategy, continuous monitoring, and regular system updates are crucial for maintaining strong cyber hygiene. While the integration of new technologies carries some inherent risks, it also unlocks substantial potential—driving process optimization, enhancing asset availability, and boosting operational efficiency.

The DS Smith Kemsley mill project underscores that digitalization, when paired with effective cybersecurity measures, offers a path to a more secure, efficient, and sustainable future for the pulp and paper industry. By investing in these technologies and collaborating with industrial automation experts, mills can unlock the full potential of digital transformation and secure their competitive edge for years to come. 


About ABB

ABB is a world leader in providing comprehensive solutions across the entire pulp and paper industry value chain, addressing everything from power to process requirements.


About the Authors

abb 30oct24 2Stefano Cinquina is Business Line Manager for Pulp and Paper
at ABB Process Industries

 

 

 


abb 30oct24 3Shankar Singh is Global Product Line Manager, Drives and Automation
at ABB Process Industries