Coalmont executed a strategic three-phase modernization of TM7's complete DC drive system over multiple years, serving as a long-term engineering partner. The project originated when the 1980s-era EMC DC drives began failing with no viable replacement for the obsolete analog boards and components. While competitors proposed a timeline exceeding one year, Coalmont offered a solution deliverable in only a few weeks—winning the project and establishing a multi-phase partnership. 

Phase 1 addressed the most critical failures by replacing the Dry End section drives with new Rockwell DC technology and installing a new ControlLogix Master PLC. To accomplish this without replacing the entire machine at once, Coalmont engineered a custom data bridge that interfaced with the fully obsolete EMC network, emulating the old drives to 'trick' the compiled EMC Master program into believing the original drives were still communicating. For Phases 2 and 3, Coalmont transitioned to ABB DCS880 DC drives—Rockwell had divested from DC drive technology, and the ABB platform provided optimal cabinet sizing to fit the existing Fan Pump enclosures. Phase 2 upgraded the Wet End and Yankee drives, with the EMC-to-ABB data bridge expanded to incorporate the additional sections. Phase 3 completed the Fan Pump drive replacements and achieved full removal of the EMC Master Controller, converting entirely to the ControlLogix PLC platform. Throughout all phases, the new drives with Ethernet/IP communications were integrated into IBA high-speed trending for advanced diagnostics. 

Through a multi‑year program, the team implemented a flexible project structure designed to respect capital budgets and progressively enhance performance. Coalmont’s multi-vendor expertise enabled selection of the optimal drive platform for each phase as project requirements evolved. Georgia-Pacific benefited from rapid response to critical equipment failures, spreading investment across budget years, validating each phase before proceeding, and ultimately achieving a completely modernized machine with standardized controls that simplifies ongoing support and future upgrades.