• Cartiera dell’Adda
• Condenser System
• Delta Formar
• Distributed Control System (DCS)
• Energy Efficiency
• Hierarchical Architecture
• ICP
• Industrial Automation
• Industrial Software Integration.
• Motor Control
• P&ID Integration
• Paperboard Alliance Group
• Papermaking Process
• PBA-APP
• Plant Maintenance
• Predictive Maintenance
• Pressa Tela
• Real-Time Monitoring
• Recycled Paper Production
• Signal Processing
• Slitter Rewinder
• Stock Preparation
• Tagging System
• Vacuum Roller

With special emphasis on ICP (Industria Cartaria Pieretti) and Cartiera dell'Adda, this thesis describes the thorough installation and integration of a Distributed Control System (DCS) into the Paper Board Alliance Group's (PBA) operating and maintenance structure. The paper summarizes the hierarchical architecture of PBA's proprietary software, PBA-APP, which facilitates component tracking, signal processing, plant-level monitoring, and maintenance. The work, which combines academic knowledge with practical industry practices, was completed during an industrial internship.
Introduction & Company Background
ICP and Cartiera dell'Adda, two Italian businesses with a long history of producing recycled paper, merged to form the Paper Board Alliance (PBA). When combined, they make up one of the biggest manufacturers of core board paper goods in Europe. Their products include corrugating sheets and recycled core boards that are used to make tissue cores, helical tubes, and edge guards. Through the use of recycled materials and energy conservation, PBA places an enormous value on sustainable manufacture.
Objectives and Scope of the Thesis
The following goals were the focus of the thesis:
•Intern at ICP to obtain hands-on experience in the papermaking sector.
•Discover how to set up and enhance the PBA-APP system for controlling components, machinery, plants, and signals.
•Encourage DCS integration for improved predictive maintenance, signal visualization, and production control.
•Address important technical concerns such signal-part dependence issues, Save Position Errors, and mismatched tagging systems.
Overview of the Paper Production Process
Recycling and pulping are the first steps in the paper-making process at ICP and Cartiera dell'Adda. Wastepaper is turned into slurry using both high-consistency (HC) and low-consistency (LC) pulpers. Machines 1 and 2 of ICP use distinct pulper setups and produce various products. Machine 2 has enhanced screening efficiency and LC pulpers for high-speed grey paper manufacturing.
The stock preparation phase then improves the fiber's qualities and eliminates impurities. After that, the pulp travels to the headbox, also known as the forming portion, where it spreads uniformly throughout the wire mesh. Machine 1 uses an older rectified roll headbox with air cushion support, whereas Machine 2 uses hydraulic headboxes for high-speed operations.
The press part strengthens the sheet and eliminates more water. In order to improve dewatering and smooth surface formation, Machine 2 employs a Delta Former system with ten rollers and a pressa tela (press fabric), whereas Machine 1 uses a six-roller arrangement. Better sheet consistency and pulp stabilization are guaranteed by Delta Former, particularly for lightweight grades.
Machine 1 has 18–19 rollers for the drying portion, whereas Machine 2 has a number of steam-heated and vacuum-assisted rollers. Before going into the steam cylinders, which are attached to condensers that use siphons to recover condensed water, the vacuum rollers remove any remaining moisture. A closed-loop cycle is used by the condenser system to maximize thermal energy efficiency and maintain pressure.
Cartiera dell'Adda uses cleaned rollers under controlled pressure and temperature to improve the gloss, smoothness, and evenness of the sheet, whereas ICP does not utilize a calendaring section. For applications involving luxury packaging, this step is crucial.
The dried paper is twisted into sizable parent rolls in the winding area. Using empty rollers on standby to switch when one is full, ICP's technology manages 6 to 8 parent rolls at once, ensuring continuous production.
After that, Slitter-Rewinder machines are used for cutting. While Machine 1 employs RIBO machines with 32 knives, Machine 2 uses RIBO 1 (50 blades, 42 used) and RIBO 3 (40 knives). For downstream packaging, the technology guarantees accurate size reduction and less waste.
Plastic film covering and first product tagging with information like size and type are part of the packaging and distribution stage. The wrapped rolls are moved downstairs by a lifting mechanism, and a tiny crane car delivers them to one of six storage buildings. Another tag with the full product data and customer information is attached for tracking and shipping after final storage.
DCS and PBA-APP System Integration
In order to automate the analysis of signals, monitor operations, and facilitate predictive maintenance, the thesis then moves on to its primary technical contribution, which involves combining Distributed Control Systems (DCS) with PBA-APP. Using fast protocols (Ethernet/IP, Profibus), DCS decentralizes control and uses operator stations to give real-time feedback. It maintains a real-time feedback loop with the user interface while operating pulpers, presses, drying cylinders, and motors in the PBA environment.
PBA-APP’s hierarchical structure includes:
•Stabilimenti (plants),
•Linee (lines),
•Aree (areas),
•Macchine (machines),
•Componenti (components),
•Segnali (signals), and
•Parti (parts).
For improved traceability, every machine and component is mapped and labeled in the system. Inverter, Direct (Diretto), Soft-Start, and Triangular motor types are better cataloged due to the tagging and numbering system, which also removes errors during part replacement.
Signal Processing and Error Handling
Signal processing is crucial in tracking:
•Power consumption (Assorbimento)
•Command (Comando di Marcia)
•Feedback (Stato di Marcia)
•Fault status (Fault)
•Speed reference (Velocità)
•Ready status (Pronto)
Through the implementation of automated tagging, part removal flexibility, and user interface enhancements, the thesis fixes current system problems such Save Position failures, tag mismatches, and manual sequence failures. In order to avoid system conflicts during maintenance, Signal-Part dependencies are now managed more effectively.
Software and Motor Control Integration
The thesis focused on creating intuitive displays for every level of the hierarchy in terms of software implementation. Additionally, the software incorporates motor and pump catalog references, making component tracking easier.
Power conversion, efficiency (η = Pout / Pin), torque (T = K × I), and voltage control utilizing SCR angle (Vdc) are all included in motor control computations. In order to ensure efficiency and minimal energy consumption, these equations support DCS algorithms that automatically adjust speed and load depending on real-time signal data.
Implementation and Results
The Depuration unit (Impianti Comuni), Machine 1, and Machine 2 all successfully linked the PBA-APP system with DCS. It made it possible:
•Enhanced motor performance with automated algorithms for control.
•Signal mapping for effective monitoring and fault identification.
•Automation of error-handling with better data integrity tools.
•Every plant, location, and signal are clearly mapped in this real-time user interface.
•Improved part management with precise catalogs and dependencies.
Additionally, the thesis offers tabular comparisons of various motor types and performance indices as well as graphical outputs (P&ID, system diagrams, and signal flow). This guarantees a solid base for maintenance personnel and operators.

Conclusion
In summary, the Paperboard Alliance Group's production and maintenance capabilities were greatly improved by the integration of PBA-APP with DCS. It improved energy efficiency, simplified process visualization, and helped operational staff make better decisions. Now that signal management and component tracking are digital, there is less chance of errors or downtime and better transitions between production phases. This work supports wider industrial automation initiatives in the papermaking industry in addition to strengthening digital transformation inside ICP and Cartiera dell'Adda.