Artificial intelligence is revolutionizing paper mills: thanks to the integration of distributed control systems, advanced analytics and digital optimization, it is possible to automatically balance quality, production and energy, reduce waste and improve operational continuity, paving the way for a more efficient, sustainable and future-ready paper industry.
The paper industry is undergoing an unprecedented digital transformation. Between volatile markets, rising energy cost pressures, sustainability targets and an increasingly digital-native workforce, paper mills must face complex challenges to maintain efficiency, quality and production continuity. In this context, artificial intelligence (AI) is emerging as a key tool to optimize processes, reduce energy consumption and improve operational management without interrupting critical activities.
ABB, a global leader in industrial automation, proposes Automation Extended, a strategic program that allows paper mills to modernize their distributed control systems (DCS) in a gradual and safe way. The approach combines an open, modular and interoperable ecosystem with the integration of advanced analytics, IoT and AI, providing operators with tools for faster decision-making, energy optimization and intelligent asset management.
The “separation-of-concerns” architecture makes it possible to preserve the core control of paper mills while new digital capabilities are implemented at scale, without interrupting mission-critical processes. This balance between operational continuity and digital innovation is today a fundamental lever for paper mills that want to face the challenge of sustainability and competitiveness in a rapidly evolving global market.
In the following interview, Shankar Singh, Global Product Line Manager at ABB for Electrification, Drives & Automation in the Pulp, Paper & Fiber sector, guides us through the opportunities offered by artificial intelligence and advanced digitalization in today’s and tomorrow’s paper mills.
How does Automation Extended respond to the specific needs of the pulp and paper industry?
“Modern paper mills depend on interconnected equipment that must operate continuously to produce products that meet increasingly demanding customer specifications. Paper mills often operate on tight margins and have tended to absorb costs associated with growing demands for quality, energy efficiency and sustainability. However, some technologies used today can be considered legacy assets and require upgrades to be future-ready. Automation Extended addresses this reality by enabling modernization without interrupting production.
Through what ABB calls a ‘separation-of-concerns’ architecture, paper mills can keep their core process control stable while progressively adding advanced digital capabilities such as analytics, artificial intelligence and asset performance management. Delivered through platforms like ABB Ability System 800xA 7.0 (distributed control system, DCS), Automation Extended unifies automation, electrification and digital technologies into a single ecosystem. This allows pulp and paper producers to move toward autonomy and optimize quality, production and energy consumption while protecting past investments. It is an attractive solution because it allows existing systems to evolve without being completely replaced.”
What are the main automation challenges in a modern paper mill?
“Paper mills face a combination of technical, economic and workforce-related challenges. Many operate with outdated automation systems that must ensure strict quality control, higher availability and lower energy intensity, often under unpredictable raw material and energy conditions. In addition, digitalization increases exposure to cybersecurity risks as IT and OT systems converge, and there is a generational workforce shift, with experienced operators retiring and digital-native engineers expecting more intuitive tools.
Engineering teams have typically struggled to integrate new capabilities into traditional automation architectures without downtime. Modern automation strategies address this with advanced analytics, AI-based decision support and optimization independent of core control, reducing risks while simultaneously addressing productivity, sustainability and skills challenges.”
How mature is digitalization in the paper sector compared to other process industries?
“It can be said that digitalization in the paper sector is unevenly advanced compared to industries such as chemicals or oil & gas, especially across different geographic markets. While quality control and level 1 process automation are well established, many paper mills still rely on fragmented digital tools layered on top of legacy systems. This limits the scale and consistency of advanced analytics and AI adoption.
However, the maturity gap is narrowing. Rising energy costs, decarbonization targets and competitive pressure are accelerating investments in advanced process control and digital optimization. Automation Extended provides a structured path for mills to evolve from partial digitalization to integrated plant-wide optimization.”
Where is there still room for improvement in efficiency and process control?
“There are still opportunities in reducing variability and coordinating decisions across the entire mill. Many producers optimize individual units—such as motors, drives or winders—but lack the ability to balance quality, productivity, energy and cost in real time.
At DS Smith’s Kemsley Paper Mill in the UK, ABB is integrating automation, electrification and digital solutions for a new pulp preparation line, part of a project to improve efficiency, reduce environmental impact and support future site growth. ABB is supplying the ABB Ability System 800xA DCS, low-voltage MCC switchboards, drives, motors, safety systems and ABB Ability Asset Performance Management software.
The technologies are integrated with ABB’s existing control architecture, providing end-to-end visibility and control over operations. This enables faster decision-making, greater reliability and optimized performance across the entire production process.”
How complex is it to modernize control systems in a 24/7 plant like a paper mill?
“Modernizing automation in a 24/7 paper mill is clearly complex because every shutdown directly impacts production, quality and customer commitments. Upgrade approaches often require plant downtime, which is difficult to justify.
Automation Extended reduces this barrier by separating the control core from digital innovation. New platforms such as System 800xA 7.0 allow control to remain operational while new digital capabilities are introduced on independent lifecycle cycles. System 800xA 7.0 is designed for predictable and safe operations with flexible upgrade paths, enabling gradual modernization—such as adding analytics, monitoring and optimization without stopping production.”
How can automation help reduce energy consumption?
“Energy efficiency in paper production is closely linked to process stability and control precision. Variability in moisture, temperature and fiber properties often leads to excessive energy consumption.
Advanced automation improves energy performance by tightening control, reducing rework and enabling faster responses to disturbance signals. Automation Extended enhances this by connecting real-time control data with analytics and optimization tools that continuously balance quality and energy consumption. The integration of automation and electrification improves visibility of energy flows, enabling mills to identify inefficiencies and prioritize corrective actions. These are not isolated energy-saving initiatives, but system-wide sustainable improvements aligned with operational and sustainability goals.”
How does process optimization influence ESG goals in paper mills today?
“Process optimization has become a key driver of ESG (Environmental, Social, Governance) performance in the paper industry. Better stability and reduced variability directly reduce raw material waste, water consumption and energy intensity, resulting in lower emissions per ton produced.
At Södra Cell’s Mörrum mill, ABB’s Quality Control System enables steam savings and can reduce production losses by 2%, equivalent to about 1,100 tons of CO₂e emissions per machine per year. By embedding sustainability into daily operational decisions, paper mills can scale ESG improvements across production rather than relying on isolated initiatives. Greater process transparency also supports regulatory compliance and safety, while more intuitive automation environments improve workforce sustainability. Optimization is therefore central to achieving measurable ESG outcomes today.”
Can digital integration support decarbonization strategies?
“Decarbonization in paper manufacturing requires coordinated control of energy, materials and production systems, which are often managed separately. Digital integration enables this coordination by connecting control systems with analytics, energy management and optimization tools.
Through IT/OT convergence, modern automation systems preserve system integrity while allowing mills to identify emission drivers and model operational trade-offs. This supports better-informed decisions on electrification, energy sourcing and process optimization. Rather than isolated carbon reduction measures, integrated automation enables decarbonization strategies to be embedded into daily operations, improving both environmental and economic performance.”
Can new automation platforms help address the shortage of skilled personnel?
“Modern platforms are essential for mill management teams, as they help address the skills shortage in the paper industry. With experienced operators retiring, knowledge gaps can compromise consistency and safety.
Technology experts support operators through data-driven environments that embed knowledge into systems via analytics, contextual guidance and decision support. This helps less experienced staff manage complex processes more confidently. Platforms like System 800xA 7.0 are designed to attract digital-native engineers while preserving established operational workflows. Automation does not replace human expertise—it complements it, helping mills maintain performance and continuity despite workforce turnover.”
What will the “digital paper mill” look like in the next 5–10 years?
“As mentioned, digitalization in the paper sector remains less mature and less uniformly implemented compared to industries such as chemicals or oil & gas, particularly in terms of integrated global optimization. While basic automation and quality control are well established, many mills still rely on fragmented digital tools layered on legacy systems, limiting large-scale adoption of advanced analytics and AI.
This gap is driving initiatives such as Modellfabrik Papier in Germany, where ABB is a founding partner contributing automation, digital solutions and analytics. The initiative applies digitalization as an integrated system, linking control, energy management and process data to improve efficiency and decarbonization. Rising energy costs and sustainability goals are accelerating similar investments, narrowing the maturity gap across the sector.”
What will be the role of technology partners like ABB in this transformation?
“ABB and other technology partners will play a strategic and long-term role in enabling digital transformation in paper manufacturing. Beyond supplying automation systems, these partners must deliver open and secure platforms that integrate automation, electrification and digitalization for decades.
With the adoption of Automation Extended on platforms like System 800xA 7.0, ABB supports uninterrupted modernization while protecting existing investments. Lifecycle services, cybersecurity and industry expertise become central to maintaining performance as technologies evolve. By aligning operational reliability, digital innovation and sustainability goals, partners help paper mills manage complexity and risk while moving toward more autonomous and efficient operations.”