Fourstones: Supporting plans for expansion

Specialism – Control

Sector – Paper

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Fourstones Group, one of the UK’s longest-established paper businesses, is growing rapidly into new product areas. The current success of the company is based on their philosophy of listening to its customers’ needs and reacting to them.

Part of this expansion is building on the success of the recently commissioned PM4 Paper Machine to produce a two-ply tissue paper by installing a 2 Ply Tissue Winder.


Provide an innovative Drive and Control solution using the latest technologies to maximise machine performance and safety, working in partnership with Fourstones design Engineers, mechanical and civil partners.


  • A complete turnkey solution for the project, meeting the demanding timescales and ever-changing requirements
  • Fully integrated Project management bringing project delivery within the tight timescales and on budget
  • Using cutting-edge technology DPS provided a fully integrated Solution
  • Design, build and test Drive, Control and Operator Panels including an Active Front End Drive System
  • Full electrical installation, testing and commissioning
  • Complete aftercare support providing remote and on-site support as required


In Detail

Machine Specifications:

  • Base Weight – 15-24 gsm
  • Maximum Unwind Diameter – 2200 mm
  • Maximum Line Speed – 1200 metres per minute
  • Sectional Speed Accuracy – +/- 0.1% of

Integrated Drive System

Unidrive M differentiates itself on performance with extremely fast current control algorithms and high switching frequencies. Active Front End (AFE) solutions deliver unparalleled torque precision and power quality.

  • Unidrive M700 200KW Active Front End
  • Unidrive M700 High Power Modular AC Drives
  • MCi210 Co-Processor modules performing the cascade speed control

Integrated Automation

Through its many innovations, the new SIMATIC S7-1500 controller sets new standards for maximized productivity. The SIMATIC S7-1500 is seamlessly integrated into the Totally Integrated Automation Portal (TIA Portal) for maximum engineering efficiency:

  • S7-1500F Programmable Automation Controller (PAC)
  • ET200SSP/F Remote I/O Interface Modules
  • TP Comfort HMI Operator Interfaces

Integrated Safety:

Fourstones are committed to safety and ensuring all machinery is designed with the highest possible safety functionality. Utilising the extensive safety features provided by both the Emerson Control techniques Drives and the Siemens S7-1500F Failsafe Controller, DPS Group provided a fully integrated safety system in accordance with EN ISO 13849-1.

Integrated Networking:

Network solutions optimised to provide the perfect solution:

  • Real-Time Ethernet (IEEE 1588 V2) uses RTMoE (Real Time Motion over Ethernet) to provide real-time drive-to-drive synchronization Profinet Industrial Ethernet
  • PROFINET with its flexible architecture and comprehensive scope of functions it enables innovative, flexible, and cost-saving machine automation