University of Maine Process Development Center

The University of Maine's Process Development Center faced increasing breakdowns from a 35-year-old paper machine drive system, with downtime incidents costing manufacturing clients up to $20,000 per event. Parts unavailability delayed return to production by a week or more, threatening the PDC's operations, budget, and reputation.

Packaging Corporation of America funded a modernization using Rockwell Automation's Paper Web Handling Coordinated Drive System Solution, including PremierSystems Toolset, Enhanced TrendPlus high-speed data acquisition, and PowerFlex 755T AC drives with predictive diagnostics. Students' capstone project developed the scope of work.

The modernization will provide reliable pilot paper machine performance, maximize machine availability, and minimize project risk. Predictive diagnostics built into the drives will provide early warnings of component life and upcoming failures, reducing unscheduled downtime and repair expenses.

• Coordinated drive system standards simplify complex paper web handling challenges from nip control to roll profile building • Embedding predictive diagnostics directly in drives eliminates the need for separate condition monitoring hardware • Industry-academia partnerships can fund critical infrastructure upgrades that benefit both sides