Sappi North America Launches Rebuilt PM2 with Valmet Automation Excellence
Sappi North America, Valmet Celebrate Successful Start-Up of Rebuilt Paper Machine 2
Successful Start-Up of Rebuilt Paper Machine 2
In May 2025, Sappi North America and Valmet achieved a major milestone with the successful start-up of the rebuilt Paper Machine 2 (PM2) at the Somerset facility in Maine, USA. The machine produced its first roll of solid bleached sulfate (SBS) board, marking a strategic shift toward packaging-grade production. Early production highlights the effectiveness of industrial automation and control systems integration, showcasing the strength of collaboration between operations and technology teams.Advanced Automation and Control Systems Integration
Valmet delivered a comprehensive rebuild of PM2, including a new OptiPress Linear press section, extended dryer modifications, and a fully upgraded finishing section. The finishing line features the OptiSizer Film size press, dual OptiCoat Roll coating heads, OptiDry Coat air dryers, OptiCalender Hard calender, OptiReel Linear reel, and OptiWin Belt winder. In addition, the facility benefits from Valmet Industrial Internet solutions, a new Quality Measurement System, web monitoring, and DNA process controls. This integration emphasizes the critical role of PLCs, DCS, and factory automation in modern paper production.Expert Collaboration Ensures Seamless Project Execution
“Valmet demonstrated deep technical expertise and project execution capabilities,” said Kirk Ross, VP Manufacturing at Sappi North America. “Their adaptability to complex industrial automation requirements and global supply chain challenges helped advance the project. We are pleased to see commercial-grade board already in production as commissioning continues.” Such close collaboration ensures that automated control systems function optimally, enabling efficient and consistent output.From PM1 to PM2: Continuous Improvement in Industrial Automation
Following the success of Project Balance, the PM1 rebuild in 2018, Project Elevate transformed PM2 into a state-of-the-art board machine. “This rebuild illustrates the power of teamwork and integrated automation solutions,” said Tuomo Rämö, Valmet Project Manager. “The sustainable conversion of PM2 enhances both process efficiency and product quality, supporting Sappi’s packaging-grade objectives.” This trend reflects the broader industrial automation movement toward smart manufacturing and connected production systems.Forward Momentum in Packaging-Grade Production
The PM2 start-up represents a key step in Sappi and Valmet’s commitment to sustainable, high-quality packaging. As the machine ramps up production, ongoing collaboration between engineering, operations, and automation teams ensures smooth optimization. Moreover, the adoption of advanced control systems, including PLC-based process management and DCS integration, positions Sappi to improve both throughput and product consistency.Applied Industrial Automation Experience
Operators and engineers report that Valmet’s automation systems enable precise tension control, coating consistency, and web monitoring, which are critical for SBS board quality. Early performance metrics indicate reduced material waste and enhanced operational efficiency. This project exemplifies practical application experience in deploying factory automation solutions for high-volume industrial processes.Application Scenarios
- High-speed paper and packaging board production with integrated PLC and DCS control.
- Real-time quality monitoring and web inspection for industrial material processing.
- Automation-driven energy efficiency and waste reduction in paper mills.
- Retrofitting legacy machines to modern automation platforms for consistent output.
