Integrating pneumatic controls for greater sustainability, productivity

 

Pneumatic controls can lead to energy efficiency, cost savings and improved overall equipment effectiveness.

Learning Objectives

• Understand how pneumatics can improve energy efficiency and overall equipment effectiveness (OEE).
• Learn how technology advances can help pneumatics improve a plant’s automation and efficiency.
• Learn how pneumatics how can reduce a facility’s overall costs and improve profitability.

Pneumatics insights

• Pneumatics is an effective and cost-competitive technology for plant automation and is applied from very simple to highly complex control solutions, directly impacting overall equipment effectiveness (OEE) of a machine or production line when sized and designed properly.
• Today’s pneumatics can address primary industry concerns, including sustainability, the labor shortage and competitive markets, by providing valuable insights and monitoring.
• Pneumatic controls address plant concerns by offering energy-efficient solutions, OEE improvement, predictive maintenance and cost savings in the field, as well as in the design phase of machines.

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Today’s plants are being held to ever-greater standards while using fewer resources and less skilled labor. To help them reach net-zero targets and produce more in greater varieties using the staff they have, many organizations are incorporating the latest control technologies, including pneumatics.

Applied from very simple to highly complex control systems, pneumatic technologies remain popular, effective and cost-competitive automation solutions. And with good reason. The pneumatic controls a machine or production line uses can directly impact overall equipment effectiveness (OEE), sustainability and costs.

The latest pneumatic technologies are designed to support the future of automation — and its innovations and challenges — from the component level up. As more facilities digitally transform, many pneumatic technologies can help provide seamless integration to higher-level control systems via the use of Fieldbus technology, embedded sensors and electronics.

In this way, they can help provide valuable insights and real-time monitoring, so the right team members receive the right information about important factors from energy use to performance levels at the right time.

To achieve the full promise pneumatics offers, it’s critical to understand the technologies available, as well as how to size and design them for maximum sustainability, productivity and cost-savings.

Figure 1: Pneumatics is an effective, fundamental and cost-competitive technology for plant automation. Courtesy: Emerson

Pneumatics save energy

As more organizations set corporate sustainability targets, plants are pressed to identify waste and optimize energy use. Due to the high-energy intensity of compressed air, many factories are implementing programs to reduce compressed air consumption. By helping operators minimize or prevent leakage and improve inefficient processes, pneumatic pressure sensors, flow meters and control solutions are playing an increasing role in these initiatives, as well as supporting the implementation of energy management systems according to ISO 50001 via adequate monitoring.

Pneumatic controls and advanced smart sensors can provide both direct and indirect information about the energy consumption of a system. If combined intelligently with industrial hardware and software for higher analytics, the overall solution can help detect leaks in their early stages and balance pneumatic devices to help reduce energy use.

This level of insight also can empower staff with key performance indicators (KPIs) and trends to make data-driven decisions that can improve energy savings, reach sustainability initiatives and reduce pneumatics maintenance intensity and air audits.

For example, there are fully assembled compressed air monitoring cabinets that include smart airflow sensors, edge hardware and connected software. The integrated solution collects and analyzes the constant inflow of data from the sensor via OPC UA and allows deeper understanding of consumption trends and possible leakage, as well as offering insight on carbon dioxide (CO₂) emissions impact. Plants can directly connect multiple smart airflow sensors to the cabinet and scale as needed. Pre-engineered and preconfigured, these cabinets make it possible for plants to install and deploy the monitoring solution to start visualizing and benchmarking compressed air consumption for a machine or production line.

In addition to the visibility and control provided by real-time pneumatic monitoring and insights, the design of pneumatic controls can help save energy. Some pneumatic control solutions are designed to allow air recycling in actuator movements, saving compressed air in each return stroke of pneumatic cylinders.

Where possible, placing pneumatic control valves in proximity of the actuators or pneumatic cylinders can further reduce compressed air. Adding pressure regulating valves to reduce pressure to the necessary levels in many applications can help save compressed air, too.

Figure 2: The latest pneumatic solutions can help plants save energy, improve OEE and reduce costs in the field as well as in the design phase of machines. Courtesy: Emerson

Improve a facility’s OEE through data access

Today’s factories face a combination of production challenges, including unplanned machine downtime, high scrap rates, unstable product quality and machine performance issues, as well as labor and skill set shortage. Pneumatics can play an important role in driving higher productivity by addressing many of these factors. It all starts with access to pneumatic data.

To maximize plant efficiency using the equipment, labor power and skill set that an organization has, it’s important that teams receive analytics and actionable insights about the pneumatic systems in machines and lines. This real-time information can help personnel across skill levels identify component health, reasons for scrap rate, product quality levels and more.

By adding smart airflow sensors to a pneumatic system or incorporating smart pneumatic devices that include embedded sensors, plants can gather and access key process and application data. Using an industrial PC, edge device or in the cloud, software can then perform analytics on gathered data points.

Operators can access resulting analytics and insights via a dashboard, gaining better visibility of and control over performance. For instance, they can adjust and optimize machine variables as needed, reducing cycle time while maximizing machine uptime, improving OEE.

The right personnel can receive this information right when it’s needed, regardless of skill and experience level. Operators can establish thresholds on key parameters, such as cylinder speed, position feedback and pressure level, and the analytics software can send alert messages when the pneumatic system operates outside of those limits.

Once received, the right personnel can take the appropriate action, preventing possible failure and minimizing unplanned downtime. In this way, taking the right action at the right time over and over again can improve overall efficiency and productivity.

As most edge gateways are prepared to work with OPC UA or message queuing telemetry transport (MQTT), accessing data from a pneumatic system in these industry-accepted formats is key. Pneumatic controls and sensors that connect via Ethernet, providing OPC UA or MQTT communication to an edge gateway for analytics, can be integral to achieve an organization’s desired plant/machine monitoring solutions.

However, implementing IO-Link is becoming a widely accepted standard. IO-Link-ready sensors and devices can be an advantage in the design and rollout of industrial internet of things (IIoT) solutions in factories due to their easy commissioning and reliable communication. IO-Link Masters allow data exchange between IO-Link-capable transmitters, sensors or devices in an automation system and are fundamental for bringing this information to the control network architecture or to the edge for further analytics.

When pneumatic valve systems are installed within a machine or located somewhere out of reach, commissioning and performing diagnostics can be inconvenient and time-consuming. A pneumatic valve system with Fieldbus technology and auto recovery module (ARM) makes it easy for technicians to perform pneumatic valve system commissioning and diagnostics from a Wi-Fi-enabled mobile phone, tablet or laptop, regardless of where the valve system is mounted. This helps manufacturers reduce production downtime, simplifies valve system commissioning and creates a path for using diagnostics for analytics.

At the component design level, proportional valves are a great example of pneumatic controls that can impact plant efficiency. Precise control of liquids and gasses makes it possible for plants to optimize machinery and processes. This can increase efficiency with production throughput as well as reduce raw material use and energy consumption.

It’s important to look for proportional valve technology that can quickly adjust output pressure or flow in relation to variable operating conditions. This technology also can provide greater flexibility of system design and operation.

Figure 3: The AVENTICS Series 615 Sentronic TWIN from Emerson is a compact, 3-way proportional pressure control valve that accurately adjusts pressure to control air and inert gas media via ATC software. Courtesy: Emerson

Reduce overall costs with pneumatics

The benefits of pneumatic monitoring are clear. By helping to minimize waste and increase productivity, pneumatics naturally helps plants reduce costs. Yet, pneumatic technologies can provide significant cost-savings in other ways.

There are well-known advantages of pneumatic technologies, like lower installation and maintenance costs. Pneumatic controls are relatively easy to maintain, and worn parts can be replaced using prepackaged spare kits. Pneumatic components have high reliability and are easy to install, lowering commission time as well. The lower capital expenditure of pneumatic systems is often an important factor for choosing this technology over others in many automation applications.

There also are less obvious ways pneumatics can help plants reduce costs, such as during the specification and machine design process. Pneumatic systems, if properly designed and sized, present reliable lasting solutions lowering machine downtime, hence providing overall cost savings. Online tools can make it easy to size actuators and valves and confirm the results of manual calculations. Additional original equipment manufacturer (OEM) tools, like cylinder finders, allow for selecting an optimal actuator series for the given parameters. Online energy consumption applications help to review the energy impact of specific configurations or selections.

More machine designers also are maximizing the advantages of pneumatic and electric technologies and incorporating hybrid solutions. In hybrid systems, electric actuators are coupled with pneumatic cylinders. By adding pneumatic cylinders with the proper pneumatic control to maintain force balance, machine manufacturers are able to size for smaller electric actuators. These hybrid solutions capture all the benefits of each technology and can present significant cost-saving opportunities.

Figure 4: Pre-engineered in preconfigured, the Emerson Compressed Air Manager includes proven AVENTICS AF2 airflow sensors, PACSystems edge gateway and advanced software and makes it easy for plants to start monitoring pneumatic systems. Courtesy: Emerson

Moving automation forward today — and tomorrow

The advantages of pneumatics are well known; however, new innovations are making this highly reliable, cost-competitive technology even better. The latest pneumatic solutions can help plants save energy, improve OEE and reduce costs in the field as well as in the design phase of machines. By integrating advanced pneumatic control solutions with real-time monitoring and analytics, plants can reach sustainability goals, empower their workforce and continue to remain competitive today and into the future.

Written by:

Franco Stephan

Source

When, how to consider low-code development for industrial applications

 

Intuitive, low-code development systems can enable the creation and customization of basic tools and dashboards to a broader set of employee skill sets, reducing the cost and time to deploy.

Learning Objectives

• Learn how low-code development allows employees that are not developers to participate in creating or customizing software.
• Accelerate development timelines for developers through low-code architectures.
• Understand how faster development and deployment saves costs and time.

 Low-code development insights

• Low-code development empowers industrial organizations to rapidly build and deploy applications, reducing downtime, enhancing flexibility and enabling seamless scaling through reusable, preconfigured components.
• By leveraging “dockerized” applications running on-premise, businesses can achieve near real-time data processing, minimize reliance on specialized developers and adapt quickly to evolving operational demands.

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In a competitive landscape, industrial organizations face constant pressure to enhance efficiency, reduce downtime and adapt to evolving business demands. The need for process agility to meet shifting customer requirements is also increasing.

Traditional software development approaches often struggle to keep pace with these requirements due to high costs, long development cycles and the need for specialized skills. Low-code applications, however, offer a compelling alternative.

By leveraging a low-code development environment with “dockerized” applications deployed and executed on-premise, industrial organizations can unlock significant cost and time savings. Dockerization — also known as containerization in coding parlance — is the process of packaging software, including its dependencies, into a standard, self-sufficient container. A Docker container is a lightweight, portable and executable package that includes everything needed to run an application, such as code, runtime, system tools, libraries and settings.

Low-code development allows users to create applications with minimal coding, allowing industrial facilities to speed and simplify the development process.

How low-code development reduces downtime, enables flexibility

Traditional software development in industrial environments often requires extensive time and resources, making it difficult to adapt to changing business needs. Low-code development platforms introduce a new level of flexibility by allowing organizations to deploy multiple instances of applications across several devices.

Additionally, these applications can forward data to the cloud when necessary, while maintaining critical functions on-premise. With features such as drag-and-drop functionality, an intuitive visual user interface and model-driven development, low-code platforms empower professional developers as well as nontechnical users to build and customize applications efficiently.

Figure 1: Customization using menu-based or drag-and-drop components means more team members can enact customizations at need. Courtesy: Siemens

This democratization of software development enables departments outside of information technology to participate in application development, ensuring faster adaptation to operational changes without relying solely on specialized developers.

One significant issue with deploying custom software to improve operations or dynamically change processes is the associated downtime. Every minute of unplanned downtime can result in substantial financial losses. Low-code applications address this issue by enabling custom applications to be created and deployed quickly and scaled dynamically.

Normal operational downtime is also reduced if low-code development applications are created for data collection and predictive maintenance at the shop floor level with real-time dashboarding and local data integration, allowing operators and decision-makers to monitor equipment status and production metrics instantaneously. This proactive approach to maintenance and monitoring significantly reduces unplanned downtime, improving operational efficiency.

Agile scaling with low-code development

Industrial settings often require custom software solutions to meet changing customer demands or evolving production goals. Expensive consultants and long lead times have plagued custom software development for industrial applications for years. Low-code applications offer a solution by enabling quick deployment and modification of applications.

Figure 2: Low-code development enables agility in automation development. Courtesy: Siemens

With preconfigured modules, templates, connectors and reusable elements, low-code applications allow organizations to develop solutions with greater efficiency. This means businesses can fast-track development cycles and deploy applications while ensuring production processes can be switched seamlessly when required.

The ability to extend application features and deploy multiple dockerized copies quickly enables businesses to scale their operations without incurring excessive costs. This scalability is a crucial benefit of low-code applications in industrial environments. Low-code applications ensure consistent quality across multiple deployments by relying on easily customizable, reusable components that have been pre-tested for performance and security.

Furthermore, these applications support continuous delivery, allowing organizations to implement improvements and updates with minimal disruption. This scalability not only reduces software development costs but also enhances long-term operational efficiency.

Skill gaps addressed by low-code development

One of the biggest challenges facing industrial human resources departments today is the shortage of skilled developers. Low-code development platforms make application development accessible to a broader range of employees with intuitive visual interfaces and model-driven development. Individuals with limited coding experience can contribute to application creation and customization and experienced developers can rapidly prototype and deploy solutions.

Figure 3: Visualized elements replace walls of code, enabling quick understanding of process changes. Courtesy: Siemens

By empowering existing talent to build and deliver applications faster, low-code platforms reduce the reliance on outsourced developers or consultants. This allows employees to customize solutions that meet their departments’ specific needs and look to internal or external development resources for only the most complex needs. This not only accelerates development timelines but also fosters better collaboration and decision-making among cross-functional teams.

The adoption of low-code applications in industrial settings is a game-changer for organizations seeking to reduce costs, minimize downtime, enhance flexibility and scale their operations efficiently. By leveraging dockerized applications that operate on-premise, businesses can eliminate cloud latency and achieve near real-time data processing, leading to improved operational performance.

Low-code platforms enable rapid application development, allowing industrial organizations to switch processes faster, adapt to changing demands and empower their workforce with accessible development tools.

With preconfigured, reusable components, these applications offer long-term cost savings while maintaining high performance and security standards. As the industrial sector continues to evolve, the ability to deploy and modify applications is increasingly essential. Low-code development provides a strategic competitive advantage, ensuring that businesses remain agile and competitive in an ever-changing landscape.

Source

Hydropower: Theoretical Foundations and Practical Applications

1. Introduction

Hydropower, or hydroelectric power, is one of the oldest and most widely used renewable energy sources. It involves converting the potential and kinetic energy of flowing water into mechanical energy and then into electricity. Due to its low greenhouse gas emissions and ability to provide reliable baseload and peak-load power, hydropower plays a vital role in modern energy systems.

This article explores the theoretical basis of hydropower generation, associated formulas, and real-world applications.

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2. Theoretical Basis of Hydropower

Hydropower is fundamentally based on the conversion of gravitational potential energy of water stored at height into mechanical energy using turbines, and then into electrical energy using generators. The process adheres to the law of conservation of energy, and its efficiency is governed by fluid dynamics and mechanical engineering principles.

2.1 Potential and Kinetic Energy

The two primary forms of energy utilized in hydropower are:

• Potential Energy (PE):
  Stored in water due to its height above a reference point.
  PE = m · g · h
  Where:
         m = mass of water (kg)
          g = acceleration due to gravity (9.81 m/s²)
          h = height of water (head) in meters

• Kinetic Energy (KE):
  Due to the velocity of flowing water (especially in run-of-river systems).
  KE = ½ · m · v²
  Where:
         v = velocity of water (m/s)
        m = mass of water (kg)

However, most conventional hydropower systems primarily harness potential energy.

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3. Hydropower Output Calculation

The theoretical power output from a hydropower system can be estimated using the following formula:

P = η · ρ · g · Q · H

Where:

           P  = electrical power output (Watts)

           η  = efficiency of the system (turbine + generator, typically 0.8–0.95)

           ρ  = density of water (~1000 kg/m³)

           g  = acceleration due to gravity (9.81 m/s²)

          Q  = volumetric flow rate (m³/s)

          H  = effective head (height difference, in meters)

This equation assumes a steady-state flow and neglects losses due to friction, turbulence, and cavitation.

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4. Types of Hydropower Systems

There are three primary types of hydropower systems:

4.1 Impoundment (Reservoir-Based) Hydropower

• Structure: Uses a dam to store water in a reservoir.

• Mechanism: Water released from the reservoir flows through a turbine, spinning it to generate electricity.

• Key Feature: Capable of supplying base and peak loads.

4.2 Run-of-River Hydropower

• Structure: Diverts a portion of a river’s flow through a channel or penstock.

• Mechanism: Utilizes the river’s natural flow and elevation drop.

• Key Feature: Minimal environmental impact, but highly flow-dependent.

4.3 Pumped Storage Hydropower

• Structure: Uses two reservoirs at different elevations.

• Mechanism: Pumps water to the upper reservoir during low demand; releases it during peak demand to generate electricity.

• Key Feature: Acts as a grid-scale battery.

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5. Turbine Types and Their Operation

The choice of turbine depends on the head and flow conditions. Common types include:

5.1 Pelton Turbine (High Head, Low Flow)

• Impulse turbine: Converts water’s kinetic energy into mechanical energy.

• Equation for torque:

  τ = r · F = r · ṁ · (v₁ − v₂)
  Where:
         τ = torque  
         r = radius  
        ṁ = mass flow rate  
        v₁ = inlet velocity of the water jet  
        v₂ = outlet velocity of the water jet

5.2 Francis Turbine (Medium Head, Medium Flow)

• Reaction turbine: Works with both kinetic and pressure energy.

• Power equation: Similar to general hydropower formula.

• Involves complex fluid mechanics and blade angle design.

5.3 Kaplan Turbine (Low Head, High Flow)

• Axial flow reaction turbine.

• Adjustable blades optimize efficiency across varying flows.

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6. Efficiency Considerations

The overall efficiency of a hydropower system is the product of the turbine, generator, and hydraulic efficiencies.

$$\eta_{\text{overall}} = \eta_{\text{turbine}} \cdot \eta_{\text{generator}} \cdot \eta_{\text{hydraulic}}$$

Typical ranges:

• Turbine: 85%–95%

• Generator: 90%–98%

• Hydraulic: varies (depends on penstock, friction, etc.)

Losses due to:

• Friction in penstocks (Darcy-Weisbach equation)

• Turbulence and vortex formation

• Cavitation (especially in Francis turbines)

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7. Real-World Applications

7.1 Power Plants

• Three Gorges Dam (China):
  Installed capacity: 22,500 MW.
  World's largest hydroelectric power station.

• Itaipu Dam (Brazil/Paraguay):
  Installed capacity: 14,000 MW.
  Supplies ~75% of Paraguay’s electricity.

7.2 Micro-Hydro Systems

• Used in remote or rural areas for local power generation.

• Typical range: 5 kW to 100 kW.

• Benefits: Off-grid capability, low environmental impact.

7.3 Integration with Smart Grids

• Pumped storage used for load balancing and frequency regulation.

• Supports integration of intermittent renewables like solar and wind.

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8. Environmental and Social Considerations

While hydropower is cleaner than fossil fuels, it still has some drawbacks:

• Ecosystem disruption: Dams alter river flow, affecting fish migration and sediment transport.

• Displacement of communities: Reservoirs can flood large areas.

• Methane emissions: From decaying biomass in tropical reservoirs.

Mitigation:

• Fish ladders, sediment flushing, environmental flow regulations.

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9. Future Trends and Innovations

• Small modular hydropower: Prefabricated units for rapid deployment.

• Hydrokinetic turbines: Extract energy from ocean currents or rivers without dams.

• Digital twin technology: Simulates turbine and dam performance for predictive maintenance.

• Hybrid systems: Combining solar PV with hydropower to optimize generation.

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10. Conclusion

Hydropower remains a cornerstone of sustainable energy systems. Its theoretical foundation is robust, relying on principles of fluid dynamics and energy conversion. Through careful design, efficiency optimization, and environmental management, hydropower can continue to provide reliable and clean energy worldwide.

Understanding its physics—from the fundamental power equation to turbine selection—is key for engineers and policy-makers looking to expand renewable energy portfolios while maintaining grid reliability.

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References

1. U.S. Department of Energy. Hydropower Basics. https://www.energy.gov/eere/water/hydropower-basics

2. Penche, C. (1998). Layman’s Guidebook on How to Develop a Small Hydro Site. European Small Hydropower Association (ESHA).

3. International Energy Agency (IEA). Hydropower Technology Brief, 2022.

Finding balance in high-output manufacturing with low energy

Finding balance in high-output manufacturing with low energy

As manufacturers face rising global demands for efficiency and environmental responsibility, they encounter a dual challenge: how to boost output while minimizing energy consumption.

By Jayme Leonard January 24, 2025

 

Learning Objectives

• Understand the role of energy efficiency in manufacturing. Identify key areas of energy consumption in manufacturing facilities, with a focus on air compression systems and recognize the environmental and financial impacts of reducing energy use.
• Explore advanced technologies for sustainable manufacturing. Analyze how automation, data analytics and IoT-enabled smart factories contribute to energy efficiency and sustainable productivity within manufacturing settings.
• Examine regulatory and financial incentives for energy efficiency. Discuss government regulations, incentives and common barriers to implementing energy-efficient practices and understand how these influence sustainable practices in the manufacturing industry.

Energy insights

• Meeting energy goals requires integrating advanced technologies and sustainable practices that not only streamline operations but also contribute to long-term savings and compliance with climate-focused regulations.
• Learn strategies to balance high-output manufacturing with low energy consumption for overall sustainable productivity.

In manufacturing, companies are under increasing pressure to enhance efficiency and productivity while simultaneously minimizing energy consumption. This dual challenge is driven by the need to stay competitive in a global market and comply with stringent environmental regulations. As the world grapples with climate change, energy conservation has become a critical component of both environmental and economic sustainability.

Global energy and climate initiatives, such as the Paris Agreement, are pushing industries to reduce their carbon footprints and adopt more sustainable practices. For manufacturers, this means finding ways to maximize output while reducing energy usage. This is not only important for compliance but also for gaining a competitive advantage in an increasingly eco-conscious market.

One of the most significant energy challenges in manufacturing is managing energy-intensive processes like air compression, which powers pneumatic tools, conveyors and assembly equipment. These systems often account for a substantial portion of a facility’s energy expenses, particularly if they are not optimized for efficiency.

To address these challenges, manufacturers are turning to advanced technologies, process innovations and renewable energy sources. By embracing these strategies, they can achieve sustainable productivity that benefits both their business and the environment.

 

Figure 1: Atlas Copco’s air quality monitor provides real-time monitoring of air purity, ensuring compliance with quality standards and enhancing operational efficiency in compressed air systems. Courtesy: Atlas Copco Compressors

Understanding energy consumption in manufacturing

To effectively minimize energy usage, it’s essential to first understand where energy is being consumed across the manufacturing industry. In manufacturing facilities, energy is typically directed toward several key areas, including machine operations, lighting, climate control and compressed air systems. Among these, air compression alone can represent 10% to 30% of a facility’s energy costs, depending on the sector and scale of production.

According to the U.S. Energy Information Administration (EIA), the manufacturing sector consumed approximately 19,436 trillion British thermal units (Btu) of energy in 2018. This consumption is distributed across various subsectors, with chemicals, petroleum and coal products, paper and primary metals being the top energy consumers On average, manufacturing facilities use 95.1 kilowatt-hours of electricity and 536,500 Btu of natural gas per square foot each year.

High energy consumption in manufacturing not only leads to increased operational costs but also has significant environmental impacts. The manufacturing industry accounts for about 20% of global greenhouse gas emissions. Reducing energy consumption is critical for both financial savings and environmental sustainability. By implementing energy-efficient practices and technologies, manufacturers can lower their energy bills and reduce their carbon footprint, contributing to global efforts to combat climate change.

By identifying these high-energy areas and deploying targeted solutions, manufacturers can establish more efficient workflows and reduce unnecessary power consumption.

 

Figure 2: Atlas Copco’s energy recovery systems capture heat generated by compressors and repurpose it for facility heating, like showers or radiators, reducing both energy costs and environmental impact. Courtesy: Atlas Copco Compressors

 

Advanced manufacturing technologies: pathways to efficiency

Technological advancements have enabled manufacturers to boost productivity while reducing energy demands. By combining automation, data analytics and smart systems, facilities are now able to achieve precise control over energy consumption, tailoring use to real-time production needs. Key technologies in this domain include:

 

Automation and robotics

Modern automated systems and robotics have transformed assembly lines, offering faster production with greater accuracy. These systems can operate only when needed, conserving energy during idle periods.

 

For example, integrating compressors with automation allows them to function only when tools are active, reducing unnecessary energy use. Automation also helps reduce human error, streamlining production and conserving power by minimizing unnecessary processes.

 

Data analytics and machine learning

Data-driven insights are invaluable in detecting inefficiencies, predicting equipment failures and optimizing schedules. In compressed air systems, for example, data analytics can highlight periods of peak usage, detect minor leaks and identify points where system pressure may be unnecessarily high. These insights allow facilities to adjust, lower pressure or schedule maintenance before energy losses accumulate, leading to cost savings and improved compressor longevity.

 

Additive manufacturing

In sectors that have adopted 3D printing and other additive manufacturing technologies, there is a noticeable reduction in both energy and material waste. By creating parts layer by layer, these methods eliminate the need for complex tooling and excess material, which traditionally require significant energy for processing and handling. Additionally, additive manufacturing often reduces reliance on air-powered equipment, contributing to lower overall energy consumption.

 

IoT and smart factories

Internet of things (IoT)-enabled factories use connected devices, sensors and smart equipment to monitor energy use in real-time. Air compressors equipped with IoT sensors can monitor their own performance, adapting pressure levels based on demand fluctuations. This dynamic control results in significant energy savings, especially during periods of low activity. Moreover, IoT data can be aggregated and analyzed to fine-tune equipment settings and identify further optimization opportunities across the facility.

 

By leveraging these advanced manufacturing technologies, companies can significantly enhance their energy efficiency while maintaining high levels of productivity. These innovations not only help in reducing operational costs but also contribute to a more sustainable manufacturing process.

 

Figure 3: Atlas Copco’s GA 450 FD 2400 VSD+ Smart AIR solution combines high-efficiency compressors with intelligent control systems, optimizing energy use and reducing operational costs for large industrial facilities. Courtesy: Atlas Copco Compressors

 

Efficient production processes

A well-designed workflow is essential for achieving sustainable productivity. By examining and rethinking how processes are structured, manufacturers can find multiple points of improvement that reduce energy use while maintaining output levels.

Lean manufacturing focuses on waste reduction, aiming to cut out unnecessary steps and resources, including energy. In lean environments, equipment such as air compressors are programmed to operate only when required, reducing energy usage during inactive periods. By setting parameters around operational needs, lean manufacturing eliminates unnecessary energy consumption.

Air compressors and other heavy equipment generate substantial heat, most of which goes to waste. By capturing and redirecting this heat, facilities can warm office spaces, pre-heat water or use it for other on-site applications. Heat recovery is particularly beneficial in colder climates, where offsetting traditional heating costs can make a notable difference in energy costs. Manufacturers can install heat exchangers to funnel compressor-generated heat into facility-wide heating systems, creating an efficient loop that repurposes waste energy

Continuous production processes generally consume less energy than batch processes, as they reduce the need for frequent start-ups and shutdowns. For air compressors, this approach means maintaining a steady, lower-pressure output rather than continually ramping up and down.

 

By implementing these efficient processes and redesigning workflows, manufacturers can significantly reduce energy consumption while maintaining high levels of productivity. These strategies not only help in lowering operational costs but also contribute to a more sustainable manufacturing process.

 

Renewable and alternative energy sources

Renewable energy adoption is a powerful strategy in the quest to reduce energy costs and environmental impact. By harnessing solar, wind or geothermal power, manufacturers can power their facilities and processes sustainably.

Solar and wind energy

Facilities equipped with solar panels or wind turbines can offset energy used for lighting, climate control and even air compressors. In this setup, smart control systems can prioritize renewable energy sources, switching to grid power only when renewable generation is insufficient. For example, a study by the National Renewable Energy Laboratory highlights how advanced manufacturing technologies can integrate renewable energy to power processes, thereby reducing reliance on traditional power sources.

Biomass and geothermal energy

Biomass and geothermal energy are also viable options for manufacturing facilities. Biomass can be particularly useful for energy-intensive industries that require high-temperature heat, such as the chemical and metal sectors. Geothermal energy, while less common, provides a stable and continuous energy source that can be used for both heating and electricity generation.

 

Benefits of renewable energy integration

Integrating renewable energy sources into manufacturing processes offers several benefits:

Cost savings: Reducing reliance on traditional energy sources can lead to significant cost savings over time.

Environmental impact: Lowering greenhouse gas emissions contributes to global efforts to combat climate change.

Energy security: Diversifying energy sources enhances energy security and reduces vulnerability to energy price fluctuations.

 

Smart equipment and high-efficiency machinery

The development of smart equipment and high-efficiency machinery marks a significant shift in the manufacturing industry, enabling companies to reduce energy consumption while maintaining or even increasing productivity. These innovations are driven by advancements in technology, including the industrial IoT (IIoT), artificial intelligence (AI) and robotics.

Industrial internet of things

The IIoT involves a network of interconnected machinery, tools and sensors that communicate with each other and the cloud to collect and share data. This connectivity allows for real-time monitoring and management of equipment, leading to improved efficiency and reduced energy consumption. For example, IIoT-enabled air compressors can adjust their operation based on real-time demand, minimizing energy waste during periods of low activity.

AI and machine learning

AI and machine learning algorithms analyze data collected from IIoT devices to optimize production processes and predict equipment maintenance needs. This predictive maintenance approach helps prevent unexpected breakdowns and reduces downtime, ensuring that machinery operates at peak efficiency. AI can also identify patterns and trends in energy usage, allowing manufacturers to implement energy-saving measures more effectively.

Robotics and automation

Robotic process automation has revolutionized manufacturing by taking on repetitive and dangerous tasks, improving product quality and reducing defects. Robots can perform tasks faster and with greater precision than human workers, leading to increased productivity and lower energy consumption.

 

For instance, robots integrated with IIoT sensors can optimize their operations based on real-time data, further enhancing energy efficiency.

 

By adopting smart equipment and high-efficiency machinery, manufacturers can significantly reduce their energy consumption and operational costs. These technologies not only enhance productivity but also contribute to a more sustainable manufacturing process.

 

Energy regulations and incentives

Government regulations and incentives play a crucial role in promoting energy efficiency in the manufacturing sector. These are designed to incentivize companies to adopt energy-efficient technologies and practices, thereby reducing their environmental impact and operational costs.

Environmental regulations set standards that manufacturers must meet to reduce their energy consumption and greenhouse gas emissions. These regulations often include mandatory energy audits, efficiency targets and reporting requirements.

For example, the European Union’s Energy Efficiency Directive requires member states to achieve specific energy savings targets through various measures, including improving industrial energy efficiency. Similarly, the U.S. Department of Energy has established energy efficiency standards for industrial equipment, such as air compressors, to ensure they operate more efficiently.

To support compliance with these regulations, governments offer various incentives and subsidies. These can include tax credits, grants and low-interest loans for companies that invest in energy-efficient technologies.

For instance, the U.S. federal government provides tax incentives for businesses that implement energy-saving measures, such as upgrading to high-efficiency motors and installing renewable energy systems.

The benefits of these regulatory measures and incentives are manifold:

Cost savings: Companies can reduce their energy bills and operational costs by adopting energy-efficient technologies.

Environmental impact: Lower energy consumption leads to reduced greenhouse gas emissions, contributing to global climate goals.

Competitive advantage: Companies that invest in energy efficiency can gain a competitive edge by reducing costs and enhancing their sustainability profile.

Innovation: Regulations and incentives drive innovation in energy-efficient technologies and practices, fostering a culture of continuous improvement.

By leveraging government regulations and incentives, manufacturers can enhance their energy efficiency, reduce costs and contribute to a more sustainable future.

 

Figure 4: Atlas Copco’s ZR 315 VSD compressor, combined with the Optimizer four.0, delivers energy-efficient, oil-free air with smart monitoring capabilities, enabling optimized performance and reduced energy consumption in industrial applications. Courtesy: Atlas Copco Compressors

 

Challenges in implementing energy efficiency regulations

Implementing energy efficiency regulations in the manufacturing sector presents several challenges. These obstacles can hinder the adoption of energy-efficient practices and technologies, despite the potential benefits. Here are some of the key challenges:

Financial barriers

One of the most significant challenges is the high upfront cost associated with energy-efficient technologies. Many manufacturers are hesitant to invest in new equipment or upgrade existing systems due to the substantial initial cost. Although these investments often lead to long-term savings, the immediate financial burden can be a deterrent, especially for small and medium-sized companies.

Lack of awareness and information

Another major barrier is the lack of awareness and information about the benefits of energy efficiency and the available technologies. This knowledge gap can prevent companies from taking the necessary steps to improve their energy performance.

Technical challenges

Implementing energy efficiency measures often requires specialized knowledge and technical expertise. Manufacturers may lack the in-house capabilities to assess their energy use and identify opportunities for improvement. Additionally, integrating new technologies into existing systems can be complex and may require significant modifications to current processes.

Market and economic barriers

Market conditions and economic factors can also pose challenges. For example, fluctuating energy prices can impact the perceived value of energy efficiency investments. When energy prices are low, the financial incentive to reduce energy consumption diminishes. Additionally, the availability of financing options for energy efficiency projects can be limited, making it difficult for companies to secure the necessary funds.

Balancing high productivity with low energy use is a critical challenge in modern manufacturing. As industries strive to meet increasing production demands while minimizing their environmental impact, the adoption of energy-efficient technologies and practices becomes essential. This balance not only helps companies comply with environmental regulations but also enhances their competitive edge in a market that increasingly values sustainability.

While the initial investment in efficient technologies and processes can be substantial, the long-term benefits far outweigh the costs. Financially, companies can achieve significant savings through reduced energy consumption and lower operational costs. Environmentally, these practices contribute to the reduction of greenhouse gas emissions and the conservation of natural resources, aligning with global climate initiatives. Competitively, manufacturers that prioritize energy efficiency can improve their market position by demonstrating a commitment to sustainability, attracting eco-conscious consumers and partners.

The journey toward energy-efficient manufacturing is not without its challenges, but the rewards — financial, environmental and competitive — make it a necessary and worthwhile endeavor. By embracing advanced technologies, optimizing production processes and fostering a culture of continuous improvement, manufacturers can achieve sustainable productivity that benefits both the business and the planet.

Jayme Leonard is a Digital Marketing Specialist at Atlas Copco Compressors.

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Jayme Leonard

Author Bio: Jayme Leonard is a Digital Marketing Specialist at Atlas Copco Compressors.