AIMPLAS, the Plastics Technology Centre based in Spain, has developed an innovative digital totem that simulates the digital passport for plastic products, which will be mandatory for marketing products in the European Union. Companies should start implementing it from 2025 to adapt to its likely entry into force the following year, although the exact date is not yet known. This tool provides consumers with essential information about the traceability, materials, recycling, and carbon footprint of the products they purchase. Additionally, this solution developed by AIMPLAS officially demonstrates that plastic products comply with all European regulations.
As an example of what this digital passport will entail, the totem includes examples of supermarket ice cream packaging, reusable cosmetic packaging, a recycled plastic pencil holder and a toy house, which, in addition to being made with at least 90% recycled plastic, aims to educate about sustainable habits and respect for nature.
Packaging and toys are framed within the priorities defined by the European Commission's Joint Research Centre for the Sustainable Products Ecodesign Regulation.
The totem, designed as an interactive screen with code and label readers, allows users to visually and intuitively explore the information that these products could present in their future digital passports. It integrates detailed data about the product's life cycle, from its origin and manufacturing process to its material components and recycling options at the end of its useful life, as well as its impact on the carbon footprint. With this demonstrator, AIMPLAS aims to raise awareness among the industry and consumers about the importance of having verified and accessible information that promotes more responsible and circular consumption.
The products identified by the European Commission as key to being included in the Sustainable Products Ecodesign Regulation (which encompasses the digital passport) are eleven final products (textiles and footwear, furniture, tyres, bed mattresses, detergents, paints and varnishes, lubricants, cosmetics, toys, fishing gear, absorbent hygiene products), and seven intermediate products (iron and steel, basic chemicals, non-ferrous metal products other than aluminium, aluminium, plastic and polymers, pulp and paper, glass). Additionally, three horizontal requirements will be considered (durability, recyclability, recycled content).
The development of this demonstrator for the future digital product passport has been made possible thanks to the support of the Valencian Institute of Business Competitiveness and Innovation (IVACE+i) with funds from the Generalitat Valenciana for the development of independent R&D activities by technology centres. It is framed within the Circular Economy Line promoted by AIMPLAS and represents a step towards transparency and sustainability in the plastics industry.
ITC Packaging and Famosa have collaborated in this development by providing relevant information from the technical sheets of the ice cream packaging and the toy. Both companies are working with AIMPLAS on the OASIS project, funded by IVACE+i within the aid program aimed at technology centres in the Valencian Community for non-economic R&D projects carried out in collaboration with companies for the 2024 fiscal year, funded by the European Regional Development Fund (ERDF) of the European Union under the 2021-2027 Operational Program.
The global market value of industrial robot installations has reached an all-time high of US$ 16.5 billion. Future demand will be driven by a number of technological innovations, market forces and new fields of business. The International Federation of Robotics reports on the top 5 trends for the robotics industry for 2025.
The trend towards artificial intelligence in robotics is growing. By leveraging diverse AI technologies, robotics can perform a wide range of tasks more efficiently:
Analytical AI enables robots to process and analyze large amounts of data collected by their sensors. This helps to manage variability and unpredictability in the external environment, in high mix/low-volume’ production as well as in public environments. Robots equipped with vision systems, for example, analyze past tasks to identify patterns and optimize their operations for greater accuracy and speed.
Robot and chip manufacturers recently are investing in the development of dedicated hardware and software that simulate real-world environments. This so-called Physical AI allows robots to train themselves in virtual environments and operate by experience, rather than programming.
These Generative AI projects aim to create a “ChatGPT moment” for Physical AI. This AI-driven robotics simulation technology will advance in traditional industrial environments as well as in service robotics applications.
Robots in the shape of human bodies have received a lot of media attention. The vision: robots will become general-purpose tools that can load a dishwasher on their own and work on an assembly line elsewhere. Start-ups are working on these humanoid general-purpose robots.
Yet, industrial manufacturers are focusing on humanoids performing single-purpose tasks only. Most of these projects are being carried out in the automotive industry, which has played a key role in pioneering robot applications throughout the history of industrial robotics, as well as in the warehousing sector. From today's perspective, however, it remains to be seen whether humanoid robots can represent an economically viable and scalable business case for industrial applications, especially when compared to existing solutions. Nevertheless, there are many applications that could inherently benefit from the humanoid form and therefore offer market potential for robotics e.g. in logistics and warehousing.
Compliance with the UN's environmental sustainability goals and corresponding regulations around the world is becoming an important requirement for inclusion on supplier whitelists. Robots play a key role in helping manufacturers achieve these goals.
In general, their ability to perform tasks with high precision reduces material waste and improves the output-input ratio of a manufacturing process. These automated systems ensure consistent quality which is essential for products designed to have long lifespans and minimal maintenance. In the production of green energy technologies such as solar panels, batteries for electric cars or recycling equipment, robots are critical to cost-effective production. They enable manufacturers to rapidly scale up production to meet growing demand without compromising quality or sustainability.
At the same time, robot technology is being improved to make the robots themselves more energy-efficient. For example, the lightweight construction of moving robot components reduces their energy consumption. Different levels of sleep mode put the hardware in an energy saving parking position. Advances in gripper technology use bionics to achieve high grip strength with almost no energy consumption.
The general manufacturing industry still has a lot of potential for robotic automation. Most manufacturing companies are small and medium-sized enterprises (SMEs). The adoption of industrial robots by SMEs is still hampered by high initial investment and total cost of ownership. Robot-as-a-Service (RaaS) business models allow enterprises to benefit from robotic automation with no fixed capital involved. RaaS providers specializing in specific industries or applications can offer sophisticated solutions quickly. In addition, low-cost robotics offers solutions for potential customers that find a high-performance robot to be oversized for their needs. Many applications have low requirements in terms of precision, payload, and service life. Low-cost robotics addresses this new “good enough” segment.
Interesting new customer segments beyond manufacturing include construction, laboratory automation and warehousing. Demand across all industries is being driven by the fact that recent crises have led to political awareness of domestic production capacity in strategically important branches. Automation allows manufacturers to nearshore production without sacrificing cost efficiency.
The global manufacturing sector continues to suffer from labour shortages according to the International Labour Organisation (ILO). One of the main drivers is demographic change, which is already burdening labor markets in leading economies such as the United States, Japan, China, the Republic of Korea, or Germany. Although the impact varies from country to country, the cumulative effect on the supply chain is a concern almost everywhere.
The use of robotics significantly reduces the impact of labour shortages in manufacturing. By automating dirty, dull, dangerous or delicate tasks, human workers can focus on more interesting and higher-value tasks. Robots perform tedious tasks such as visual quality inspection, hazardous painting or heavy lifting. Technological innovations in robotics such as ease of use, collaborative robots or mobile manipulators help to fill gaps when and where needed.
As a result of the strategic partnership, around 800 sales and service employees from SICK transfer to Endress+Hauser across 42 countries. The collaboration in process automation will allow customers to access a broader range of products from a single source and benefit from enhanced expertise in gas measurement technology. With its global sales network, Endress+Hauser will access new customers, reach additional industries and tap into further application areas.
The production and further development of the gas analyzers and flowmeters were brought together under the umbrella of Endress+Hauser SICK GmbH+Co. KG. SICK and Endress+Hauser will each hold 50 percent of the joint venture as of 1 March 2025. The company employs around 730 people at several German sites and will collaborate closely with Endress+Hauser’s product centers to drive product innovation and meet evolving market demands.
Hundreds of employees from both companies have been preparing for the smooth transition of the business in recent months. Now the gas measurement sales and service teams at Endress+Hauser are ready to provide support. Since 1 January 2025, Endress+Hauser has been exclusively marketing SICK’s gas analysis and flow measurement technology worldwide. In China, the transition will not take place until 1 March 2025 for technical reasons. In Türkiye and Saudi Arabia, sales and service will be transferred to Endress+Hauser in the first quarter.
Dr Peter Selders, CEO of the Endress+Hauser Group and Dr Mats Gökstorp, chairman of the executive board of SICK AG expressed their gratitude to employees on both sides who contributed to establish this partnership. “Above all, we thank all the employees who have made the process automation business strong with their expertise and commitment and will continue this success story with the strategic partnership,” said Mats Gökstorp. Peter Selders added: “We look forward to working with the people joining us and the joint venture to build something new and make this partnership a success.”
ABB’s CEM-DAS is the first data acquisition and handling system (DAHS) on the market to successfully pass testing in line with EN 17255, the first international standard for DAHS in emissions monitoring. With the successful completion of the tests, ABB becomes the first company to offer a complete package of continuous gas analysis and DAHS systems fully compliant with international standards.
DAHS are computer-based systems that collect and process information on air pollutants measured by continuous emissions monitoring systems (CEMS). The measurements are processed to produce reports demonstrating compliance with regulatory emissions limits.
The new standard allows plant operators across industries such as power, oil & gas, waste-to-energy, cement and chemicals to choose DAHS that have been assessed by an independent testing laboratory and certified by an independent certification body.
“ABB’s CEM-DAS is a key system for reporting emissions to authorities,” said Jean-René Roy, Global Business Line Manager, ABB Measurement & Analytics. “The fact that CEM-DAS is now successfully tested according to the first international DAHS standard provides plant operators with the same confidence that they have in ABB’s certified continuous emission monitoring systems. At a time of increasing environmental awareness and tightening regulatory requirements, CEM-DAS is crucial for ensuring environmental stewardship and regulatory compliance.”
Carried out over a period of six months, the tests were conducted by TÜV Rheinland Energy Environment, GmbH, an accredited laboratory that tests, inspects and certifies technical systems and facilities. The tests showed that CEM-DAS’s emissions reporting provided reproducible results regardless of vendor-specific data processing methods. It is expected that the EN 17255 standard will improve the quality of data acquisition and handling system reporting globally by providing standardized protocols for data collection, validation and reporting. It will also help ensure consistency and accuracy across different systems and regions.
The EU Packaging and Packaging Waste Regulation (PPWR) aims to make the packaging industry more sustainable and to reduce the negative impact of packaging waste on the environment. However, it is posing significant challenges for manufacturers due to the extremely tight deadlines, the varying implementation schedules and the lack of detailed regulations at the moment. Companies need to assess as quickly as possible how they will respond to the often complex requirements. This can have far-reaching implications for their packaging and manufacturing processes - and requires efficient, compliant implementation, which PCC offers a wide range of support for.
As Michael Graf, Head of the PCC and a sustainability expert at Schubert, explains: “Manufacturers are dealing with very practical considerations. What are the implications of packaging a chocolate bar in paper instead of a flowpack in the future? Or how does an existing cartoning machine run when blanks are resized, when they behave differently in the machine or when they can no longer be glued? These issues are significant and require answers along the entire value chain.”
This is where the Packaging Competence Centre fits in. The key advantage of the PCC is that it can offer regulatory advice, packaging development and machine feasibility - all from a single source - thanks to the combined expertise of the two companies. While the experts from bp Consultants clarify the PPWR and explain its impact on the respective packaging portfolio, Schubert evaluates the machinability of new packaging solutions, thus ensuring the automation that is essential for packaging processes. Marcel Kiessling, Managing Director of Gerhard Schubert GmbH, points out: “As a leading machine manufacturing company, we are proud to be working with Berndt+Partner, an equally leading-edge consulting group for packaging issues in Europe. The Packaging Competence Center is a collaborative partnership that provides technical consulting services for packaging processes and technologies – all targeted towards making our customers’ production processes more efficient and sustainable.
If, for example, a manufacturer wants to switch its packaging materials to paper or recyclable mono films, the PCC offers a so-called Impact Check. During this process, the experts analyse, as part of their evaluation, whether a manufacturer’s existing packaging range meets the regulatory requirements or whether it needs to be improved. Once all questions have been clarified, manufacturers can develop a new packaging design, with support available if desired from Berndt+Partner Creality, a subsidiary of the Berndt+Partner Group that specialises in packaging design and branding. The PCC always takes automated packaging processes into account.
Once the modified packaging concept has been finalised, Schubert tests it on its own machines in Crailsheim. The packaging machine manufacturer determines whether the new materials and formats can still be processed efficiently and whether they may require technological adjustments. Michael Graf believes it is vitally important to take a holistic approach: “Sustainability – the basic idea behind our Mission Blue Initiative – has to incorporate systems and upstream steps such as design to ensure that a solution is consistently ecological. Packaging made of paper or mono film alone is not enough.” Once the consulting, design and testing are complete, the PCC continues to support manufacturers. “Regulations change quickly, so manufacturers will soon have new questions for which they want equally creative answers – and they will find them at the PCC,” concludes Matthias Giebel, Partner at bp Consultants, a subsidiary of the Berndt+Partner Group.
The DynamiQ-X gas analyzers were tested by NMi in the Netherlands, a leading notified body in Europe for the testing and certification of measuring instruments with ISO 17025 approval. The tests included evaluating metrological characteristics over a wide temperature range and assessing performance under dynamic environmental conditions, including mechanical and electrical influences. Additionally, the software and the firmware are investigated for control, data processing and communication in accordance with the WELMEC guide.
The OIML R140/MID approval simplifies the approval process for systems according to national and international legislation among member states. It provides reduced risks, greater time savings and improved cost efficiency to system integrators.
OIML R140/MID approval for DynamiQ-X NG2210 and DynamiQ-X NG2220 The OIML R140/MID approval is valid for both gas chromatographs, the DynamiQ-X NG2210 and the DynamiQ-X NG2220. These are compact Ex-certified process gas chromatographs for composition control and custody transfer purposes. The NG2210 version provides natural gas C6+ composition analysis and calorific value calculations and the NG2220 performs the same analysis for natural gas blended with hydrogen in concentrations of up to 20%.
The independent manufacturer C. Otto Gehrckens GmbH & Co. KG (COG), one of the leading suppliers of precision seals in Germany, is facing a transition in management. Ingo Metzger, the Technical Managing Director of the long-established family business, will be joining the Advisory Board at the end of the year after 30 years of active management. His new successor, Dr Jan Cord Becker, will jointly lead the business together with Jan Metzger, who continues to head up the commercial operations of the company.
Dr Jan Cord Becker is a mechanical engineer and has more than 20 years of professional experience as a managing director in leading positions in industrial companies. One focus in his previous role, was the successful optimisation and reorganisation of an internationally active family business in the tool industry.
Ingo and Jan Metzger commented: “With Jan Cord Becker, we have gained a proven expert in corporate development who will lead the company with great strategic foresight and will continue our successful path of further growth.”
C.Otto Gehrckens looks back on a successful company history of more than 150 years and is still family-owned and -managed. Jan Metzger represents the fifth generation of family in the company.
Salmon is one of the most popular edible fish in the world. In the EU alone, the largest market for salmon, over one million tonnes were consumed in 2023. The majority of salmon traded worldwide today comes from aquacultures where the fish are bred under controlled conditions. This involves the use of large net cages anchored to the seabed, which provide space for up to one million fish. Around 70 per cent of global salmon production takes place in this way, mainly in the Norwegian fjords and off the coast of Chile.
However, this form of intensive farming provides ideal conditions for the salmon louse, a parasite that significantly impairs the health of the fish. Combating this pest and the resulting damage costs several hundred million euros each year - up to 10 per cent of total production expenditure.
In order to minimise these financial losses, the Norwegian company Harbor AS has developed a robust and now patented preventive solution against salmon lice under the name Harbor Fence. Verification and pilot tests were carried out in large commercial facilities between 2015 and 2019. Harbor has tested a successful technical and mechanical verification over two generations of salmon in commercial pilot plants, which was completed in spring 2020.
Research has shown that lice larvae lose their ability to attach to salmon when exposed to small electromagnetic fields. Harbor Fence utilises this effect through an enclosing electromagnetic field that is stretched around the cage. The field takes the form of an open fence and neutralises the lice larvae on their way into the cage. Harbor Fence is now in commercial operation and supplies several customers along the entire Norwegian coast. Installation and service are carried out by our own teams.
In addition, a good flow of water helps to neutralise the lice larvae produced in the cage when they emerge from the harbour fence system. This helps to reduce the infection of neighbouring cages, other sites and wild salmon. Harbor Fence has a localised effect and does not harm the fish within the aquaculture.
Harbor AS enlisted the expertise of LAPP Norway to develop this solution. Together with LAPP Muller and the LAPP Engineering & Advanced Technology department, the Norwegian specialists developed a special electrode cable. This was used to construct a kind of "fence" of thin electrodes that are attached around the outside of the entire net pen. The system poses no risk to the health of the salmon, partly due to the low voltage and the fact that it is attached to the outside of the net pen.
The electrode specially developed by LAPP is a semi-conductive power cable that conducts electricity and forms an electromagnetic field or barrier. By hanging the electrodes in a row one behind the other, they form an electromagnetic open fence and an open-air protection that acts as an external fuse. "The challenge was to design the cables in such a way that they could withstand seawater without significantly losing their effectiveness during their intended service life," says Lars Nilsen, Product Manager at LAPP Norway. LAPP Norway has already supplied more than 130 kilometres of electrodes for such salmon fences.
The electrodes, which hang in the sea at a distance of 12 - 17 centimetres outside the net, are connected to a power / control cabinet. This controls the frequency and length of the pulses that are sent via the electrodes. The control cabinet continuously transmits real-time data on the state of the sea as a basis for optimisation, monitoring and control. Normal net pens today are equipped with two automation and control boxes. A Harbour Fence installation has an annual power consumption of 9,000 kWh. The standard depth for a Harbour Fence system installation is 10 metres.
Harbor Fence is just as suitable for plastic cages as it is for steel cages. The company concludes service contracts with its customers and ensures that the fence functions properly. Harbor also takes care of returns and the repair or replacement of the system if necessary. In addition, a remote monitoring solution can provide real-time hydrographic data such as salinity, temperature and current velocity. This data can be used to optimise the current pulse and current consumption in the fence. The systems are constantly being further developed, as are the electrode materials used.
Christian Fritzland is project manager at Harbor. He is experiencing high demand for Harbor Fence: "We have also received international enquiries from Canada, Chile and Scotland. We are continuously working on product development and are pursuing several interesting avenues. Some of these involve easier assembly and disassembly as well as remote monitoring and control of the power cabinets." Such a system could also provide early warning of other undesirable events, such as sudden fouling or increasing algae growth. Fritzland adds: "If the lice still get into the cages, complementary solutions such as cleaner fish and lasers can work well with the electric fence. Together with cleaner fish or lasers, the system is a very important measure against lice that is not only environmentally friendly, but also cost-effective."
Developed by the manufacturer, the UK’s first in-house hydrogen test kiln is used primarily in the production process of ceramics, pottery and bricks. Its key feature is that it can scale its operation with a fuel mix of 20% hydrogen or more. The test kiln has been developed to support businesses making the transition to the increased use of hydrogen.
Currently in the UK, kilns are primarily fired with natural gas, but the government is considering plans to blend the supply of gas in the network with 20% hydrogen. For brick and ceramic manufacturing, the type and concentration of gas impacts the curing process. The new kiln design is enabling manufacturers to test their production processes with a hydrogen blend and monitor the effects on the quality of their products, in advance of a government switch-over.
The new test kiln can currently control the gas mix up to around 40% hydrogen, though there is a plan for the potential use of 100% concentration. This scalability is enabling brick and ceramic producers to confirm operational performance before investing in hydrogen-fuelled, industrial-scale production lines.
A key challenge in the development of the new kiln has been the integration and control of the gas blend. High accuracy is required to ensure exacting regulation of the hydrogen concentration, to replicate large-scale, operational conditions. Control reliability also has to be repeatable for manufacturing processes lasting up to 24 hours or more.
A programmable logic controller (PLC) manages the kiln’s overall gas blend process, including temperature and pressure sensors. To design the control system specifically for the high accuracy-dependent hydrogen regulation, the manufacturer partnered with flow control specialist Bürkert. In order to ensure precise modulation, Bürkert integrated a Type 8742 mass flow controller (MFC) to manage the single channel flow of hydrogen.
The kiln requires a hydrogen flow rate of 22 m³ per hour at 3 bar, and the MFC offers a control span of a 50:1 turndown, enabling it to reduce flow down to 1/50th of the total level as required. Crucially, the MFC ensures a measuring accuracy deviation as low as ±0.3%, and repeatability down to just ±0.1%. This precision is enabling customers to test exacting hydrogen concentrations to optimise their processes.
The MFC connects to the kiln’s PLC master controller via a Bürkert ME43 gateway. The communications gateway converts the MFC’s CANopen signal to the Profinet protocol, enabling seamless communication between the devices. Ease of set up and reliable communications in integration of the hydrogen flow controller to the kiln’s main automation controller was vital.
As the hydrogen test kiln is regularly used with different brick and ceramic manufacturers, they each have their own control parameters. The ME43 enables plug-and-play connectivity to the master controller, providing the ability to make fast changes.
Since the Bürkert communications gateway converts the signal to the desired communications protocol, this removes the cost of additional licences required to extend integration to the PLC using same-vendor devices. This is particularly advantageous to enable scaling up of the technology in the future for use on industrial-sized kilns and furnaces. For full manufacturing production applications, the Bürkert communications gateway also enables remote connectivity and management of the production process.
The brick and ceramics manufacturers who have so far tested hydrogen use at 20% concentration have reported positive results, with no significant differences to the outcome compared to using 100% natural gas. The next stage is the widespread testing of concentrations up to 40% and beyond.
Economically, industry currently remains reliant on natural gas, but proliferation of hydrogen could eventually see price of this gas fall to parity, or even lower, than current gas prices. Importantly, expanded use of hydrogen could create a more sustainable outcome, particularly if green hydrogen, created from renewable sources, is increasingly used.
The new VisuNet GXP is equipped with an RFID reader fully integrated into the display unit and supports common RFID-based access cards such as MIFARE® and LEGIC®. The authentication process can therefore be handled via the company ID card, for example. This not only optimizes the login process, but also improves security by clearly defining and automatically managing access rights. Companies that already use RFID card systems can continue to use their existing access cards without having to introduce additional hardware or new media.
Due to the integrated RFID reader, the device can be integrated into modern security concepts such as multi-factor authentication, in which several identification features are combined. Companies that need to comply with the highest security standards can supplement the VisuNet GXP with additional identification methods such as password entry or biometric recognition. This functionality is particularly important in industries with strict security requirements, including the pharmaceutical industry, chemical companies and the oil and gas sector, where regulatory requirements demand unique identification of operators.
The VisuNet GXP also offers five capacitive front buttons that enable quick and easy operation. The buttons are configurable and allow frequently used functions to be executed directly. For example, one button can be assigned as a home button to quickly return to the standard view. Another function allows the display brightness to be adjusted, which ensures optimum readability, especially in changing light conditions. To avoid unintentional inputs, the touch screen can be deactivated via one of the front buttons, for example during cleaning. The device also has a power button that can be flexibly configured or deactivated as required to prevent accidental switch-off during operation.
The combination of robust RFID technology, capacitive front buttons for intuitive operation, and flexible system integration makes the VisuNet GXP a future-ready solution for industrial environments with increased security requirements. Plant operators not only benefit from faster and more convenient logon, but can also adapt their access concepts to new security standards in the long term without having to completely replace existing infrastructure.
The modularly designed VisuNet GXP is divided into three interchangeable units, each of which is independently approved for use in hazardous areas: The display unit, the computing unit, and the power supply. This concept allows individual modules to be replaced directly in Zone 1/21 without having to remove the entire operator workstation. Anyone planning an upgrade can therefore integrate the latest hardware into the existing HMI system and extend the lifetime of the VisuNet GXP in the long term. If a component fails, the downtime is significantly reduced because the entire device does not have to be disconnected from the process. This flexibility means a high level of investment security for operators, as they can make hardware changes step by step and therefore always remain up to date.
The VisuNet GXP is not only versatile on the hardware side, but also on the software side. In addition to Pepperl+Fuchs' own VisuNet RM Shell 6, which is based on Windows 10 IoT Enterprise LTSC 2021, the device also supports IGEL OS 11 and IGEL OS 12 based on Linux. The devices are also ThinManager Ready. This openness means that the VisuNet GXP can be seamlessly integrated into existing IT structures. Plant planners and engineers pursuing modern automation approaches benefit from a sustainable solution that can be efficiently adapted to individual requirements due to the modular hardware approach and broad software compatibility.
The RFID reader built into the VisuNet GXP is based on the RFID20 component from Pepperl+Fuchs. As a stand-alone component, it is certified for use in ATEX/IECEx Zone 2/22 and Division 2. It can be integrated into stainless steel housings and used directly in pharmaceutical and hygienic production environments. The RFID20 component is compatible with leading authentication systems such as PM-Logon from Siemens, LogOnPlus from Obion, and the Connected Worker Platform from Nymi, enabling easy integration into existing safety and identification solutions.
PM-Logon from Siemens plays a particularly important role in SIMATIC control systems. This software facilitates the logon process by automatically assigning a user identity to an RFID card. As soon as an authorized person holds their card up to the reader, they can log in to the target system without having to enter a password manually. This speeds up the logon process, minimizes operating errors, and at the same time meets high security requirements in production environments.
In addition to PM-Logon, the RFID20 component is compatible with LogOnPlus from Obion, a modular client-server solution that integrates seamlessly into various process control systems. It also supports Nymi's Connected Worker Platform, which enables biometric and wearable authentication, further increasing security standards in sensitive industries such as life sciences.
With the combination of an integrated RFID reader, capacitive front keys for flexible operation, and a modular hardware design, the VisuNet GXP is a particularly attractive solution for demanding applications in Zone 1/21. Plant operators who require a forward-looking HMI platform with full RFID functionality in a hazardous environment are provided with an extremely robust, reliable, and expandable system. The fast, secure, and uncomplicated authentication via RFID card optimizes processes by minimizing sources of fault and reducing downtimes. This represents a decisive economic advantage for smooth operations. Compatibility with authentication systems such as PM-Logon, LogOnPlus, or the Connected Worker Platform ensures smooth integration into existing IT infrastructures. This makes the VisuNet GXP the optimal choice for plant operators who need future-oriented, flexible, and seamlessly integrable HMIs for demanding environments.
Author: Yannik Klein, Pepperl+Fuchs
Siemens announced a significant update to its industrial-grade private 5G infrastructure solution, that will enable manufacturers to cover larger industrial areas with enhanced connectivity capabilities. The expanded solution now supports up to 24 radio units, with each unit capable of covering approximately 5,000 m².
The updated private 5G infrastructure is now available in multiple countries including Germany, Sweden, Netherlands, Switzerland, Denmark, Austria, and Brazil, and there are plans to expand to additional countries throughout 2025. When the initial version of Siemens’ private 5G infrastructure was launched in 2023, it was exclusively available in Germany. To complement the infrastructure expansion, Siemens is also introducing the new compact Scalance MUB852-1, an entry-level 5G router for cabinet use with IP20 protection class, part of the Siemens Xcelerator portfolio. The router matches the Siemens Simatic ET200 I/O footprint and integrates seamlessly into Siemens’ Totally Integrated Automation (TIA) landscape.
"Our enhanced private 5G infrastructure solution represents another milestone in connected production," said Axel Lorenz, CEO of Process Automation at Siemens.
"By enabling coverage of larger industrial areas while maintaining the same reliable connectivity, we're meeting the growing demands of modern manufacturing environments."
The enhanced solution comes at a crucial time, when reliable wireless connectivity in factory environments is facing increasing challenges. The traditional unlicensed Wi-Fi spectrum often becomes overloaded in crowded settings, leading to communication outages and potential production shutdowns. Siemens' private 5G infrastructure directly addresses these challenges by providing a dedicated, network solution for mission-critical applications. Private 5G networks also create the flexible communication infrastructure needed to easily integrate smart sensors and edge devices, enabling data-driven decisions on the shop floor through artificial intelligence applications.
Building on these capabilities, Siemens has developed this solution specifically for industrial use cases and requirements. The system features an innovative, user-friendly approach with a straightforward configuration process that only requires about 20 variables in a single comprehensive Web user interface. A clearly arranged dashboard offers a comprehensive overview of the network status making it accessible even for non-IT users. While many industry solutions require specialized expertise, Siemens' approach prioritizes user-friendly operation and simple implementation to support mission- and business-critical applications.
This private 5G infrastructure will be extremely valuable across a variety of industrial sectors, including manufacturing, food and beverage, pharmaceuticals, intralogistics, heavy industries, and mining. The system allows companies to operate their networks independently without relying on third-party providers, which ensures enhanced cybersecurity and data privacy thanks to on-site installation. Users can flexibly modify their networks to meet changing demands and perform fast troubleshooting when necessary.
"The industrial world is moving away from the 'one-size-fits-all' approach to wireless connectivity. With our private industrial 5G infrastructure, we're giving manufacturers the tools to design their digital backbone exactly the way they need to, whether they're running a single production line or an entire smart factory complex,” Lorenz said.
The combined heat and power plant was originally built in 1976 for fossil fuels. To continue working reliably in the future, the plant operated by Stockholm Exergi, the Swedish capital’s energy supplier, had to be modernised. A large-scale retrofit project was initiated that will extend the service life of the plant by a further 20 years and help to meet Stockholm’s growing demand for heating and electricity during the cold winter months. The boiler was converted so that it can be operated with renewable fuels such as bio-oil.
Within the scope of this project, AUMA received the order to automate 241 valves. AUMA’s broad portfolio offered the perfect electric actuation solution for each application: SA and SQ actuators with AC 01.2 actuator controls, sometimes combined with GST and GS gearboxes or LE linear units, as well as SAR and SARV modulating actuators for more stringent control requirements. AUMA service experts dismantled the old devices on site and installed and commissioned the new devices.
The actuators are used to control all the processes in the combined heat and power plant, from the fuel supply, feed water and steam systems to flue gas cleaning and feeding into the district heating network. Using AUMA actuators with integral Profinet communications brought major advantages: high reliability thanks to integrated redundancy, easy and flexible integration, and advanced diagnostic options. Overall, the AUMA actuators help to improve the efficiency, reliability and safety of the CHP plant and reduce operating costs.
The project shows how retrofitting state-of-the-art, high-performance valve actuation technology can ensure efficient and sustainable plant operation. As part of AUMA’s global sales and service network, AUMA experts are available worldwide to support plant designers and operators with comprehensive services on retrofit projects of any kind and scale. As in this project, the AUMA experts typically take care of the entire project management, from a detailed analysis of the requirements, through selection and sizing of suitable AUMA actuators, to installation and commissioning on site.
ControlAir is pleased to announce the release of the CG330 and CG340 gas regulators. This innovative range has been specifically designed to meet the growing demand for low emission solutions in industrial applications using compressed gases such as inert gases, natural gas and other sensitive media. The range of compressed gas filter regulators is designed to provide accurate pressure control with near-zero atmospheric leakage under dynamic or steady-state flow conditions. Ideal for applications that must comply with stringent fugitive emission regulations, these rugged regulators provide users with exceptional reliability, operational efficiency and environmental safety.
The series ensures near-zero atmospheric leakage (less than 0.1 scfh (0.05 Nl/min)) for regulatory compliance. They are available in 1/4" and 1/2" NPT port sizes with output pressure ranges of 0-30 psig, 0-60 psig and 0-120 psig to meet various application requirements. Constructed of die-cast aluminium alloy with an iridite and baked epoxy finish for long-term performance in harsh environments and a wide range of media compatibility, the regulators can handle air, inert gas and sweet natural gas within temperature limits of 0°F to 160°F (manual drain) or 32°F to 160°F (automatic drain).
The CG330/CG340 regulators are ideal for industries such as oil and gas, chemical processing and any operation where precise pressure control and environmental safety are critical.
Emerson recently partnered with Laramie Energy to help the Colorado-based oil and gas producer comply with state and federal emissions regulations. Using ASCO Zero-Emission Electric Dump Valves, the only all-electric solution for separators, scrubbers and compression units, Emerson helped Laramie Energy achieve compliance by eliminating both vented and fugitive emissions from the liquid dump stage of its separation process.
Conventional dump valves are often actuated by well gas, which can leak into the atmosphere as vented and fugitive emissions. Some states, including Colorado, have emissions regulations that include fines for non-compliance, and the Environmental Protection Agency (EPA) has established a waste emissions fee for methane emissions that exceed certain thresholds.
When fugitive emissions are detected, the EPA requires oil and gas producers to report their greenhouse gas data and to conduct testing, surveys and repairs. Companies that fall out of compliance must pay costly fines and waste subsequent downtime to restore to return to compliance.
In comparison, ASCO zero-emission electric dump valves use ultra-low-power electric actuation, which removes the need to vent well gas in upstream applications. And, unlike traditional dump valves, they are fugitive-emissions-free by design because they have no valve packing. With precise control, ASCO electric dump valves actuate in 50 to 75 milliseconds compared to conventional valves that take several seconds, thus virtually eliminating any chance of gas blowby. This helped Laramie Energy better maintain the static pressure of their vessels which ultimately led to an increase in natural gas production. The valves also use 1.2 watts (W) of energy compared to a conventional electric retrofit kit that uses 96 W, reducing valve power usage by 98.75%.
Though initially designed for legacy well sites, these fully electric dump valves can help oil and gas companies achieve compliance and avoid red tape on both newly drilled production sites and existing production sites to meet new standards. The solution provides a cost-effective, maintenance-free alternative to meet compliance when compared to other solutions like instrument air, nitrogen and electric retrofit kits.
Laramie Energy focuses on developing unconventional oil and gas reserves within the Rocky Mountains, operating roughly 1,500 wells. The company installed ASCO electric dump valves in newly drilled wells while updating its legacy wells with the solution. Beyond ensuring compliance, the valves have provided additional benefits, including less maintenance and greater well efficiency.
The pneumatically actuated stainless steel (1.4408, 1.4308) flange valves Type 7032 from Schubert & Salzer Control Systems are suitable for shutting off neutral and slightly aggressive liquids and gases quickly and safely. The sturdy and compactly designed valves are usable for high operating pressures and are characterised by particularly high switching performance, leak-tightness and reliability.
Their wide usage range encompasses media temperatures from -30 °C to 200 °C. The previous nominal size range (DN15-80) has been extended by the new nominal sizes DN100, DN125 and DN150, which are designed for a nominal pressure of PN16. Their compact design corresponds to the EN 1092-1 flange standard and guarantees simple integration into common pipeline systems.
During a month-long field test conducted by KECO in collaboration with a leading vapor recovery unit (VRU) manufacturer, KECO's OxyHound process gas analyzer demonstrated superior performance compared to traditional electrochemical analyzers. The test focused on measuring oxygen levels in gas streams. During the test, both the OxyHound and a conventional electrochemical analyser were set up to measure oxygen levels in a gas stream. The data collected was integrated into the VRU company's SCADA system, which took readings every two minutes. The results showed that the OxyHound significantly outperformed the electrochemical analyser in terms of accuracy and reliability.
The OxyHound uses advanced quench luminescence technology for gas sampling to ensure accurate oxygen measurement. This method uses the decay of light emitted by a specific luminophore over time to accurately determine the partial pressure of oxygen. The analyser tracks changes in light phase and intensity between the excitation light and the fluorescence response. The on-board computer uses this data to calculate oxygen levels in real time.
Long sensor life
A cost analysis between the two technologies revealed that the electrochemical instruments required cell replacement at least twice a year due to exposure to water. The estimated annual replacement cost was approximately $1,000. In contrast, OxyHound's quench luminescence technology is non-consumable, requires no consumables and only occasional sensor recalibration. These factors significantly reduced both cost and labour.
While electrochemical analysers are susceptible to liquid contamination, the OxyHound can operate in environments with contaminants such as H2S, CO2, H2, propylene, methanol and ethanol mixtures. Its insensitivity to various gases makes it ideal for applications in natural gas pipelines, refineries, biogas production, chemical plants, landfills, wastewater treatment, manufacturing, food and beverage, and renewable energy sectors. The analyser is designed for use in Division 2 & Zone 2 hazardous locations.
Hilscher has introduced a new SPE Media Switch designed to integrate Single Pair Ethernet (SPE) into industrial Ethernet networks. The new SPE Media Switch, based on Hilscher’s multiprotocol-capable netX90 communication controller, provides seamless connectivity for SPE applications with PROFINET, Open Modbus/TCP, and EtherNet/IP networks. This ready-to-use device offers a cost-effective solution for implementing SPE in industrial field environments.
The SPE Media Switch enables seamless IP-based communication from sensors to the cloud without the need for additional, expensive network components. This allows devices to be easily and affordably connected over distances of up to 1.000 meters using the 10BASE-T1L standard, making it ideal for large production facilities or widely distributed applications.
As a member of both the Single Pair Ethernet System Alliance (SPE SA) and the SPE Industrial Partner Network (SPE PN), Hilscher supports both SPE connector standards. The SPE Media Switch is compatible with IEC 63171-2 (SPE SA) and IEC 63171-6 (SPE PN) connectors, giving users the flexibility to choose the option that best meets their needs.
The SPE Media Switch is based on Hilscher’s netX 90 communication controller, offering users several advantages:
In PROFINET and EtherNet/IP networks, the SPE Media Switch can operate in either transparent or configured modes. In transparent mode, data is simply routed through the SPE Media Switch, which is invisible to the controller. In configured mode, the switch is mapped in the controller and can, for example, be assigned a fixed IP address. For Open Modbus/TCP networks, only transparent mode is available.
To ensure stable network performance and reliable data transfer, Hilscher has integrated a rate limiter function into the SPE Media Switch. This feature helps prevent data loss when bandwidth decreases from 100 Mbit Industrial Ethernet to 10 Mbit SPE.
The unique rate limiter function manages network traffic during high data loads by prioritizing and processing Industrial Ethernet frames based on predefined parameters. Additionally, a flow meter mechanism allocates bandwidth across various types of messages. For example, a minimum of 5 Mbit can be reserved for Industrial Ethernet messages from PROFINET and EtherNet/IP in the SPE network, while up to 3 Mbit is allocated to unicast messages, and a maximum of 1 Mbit for multicast or broadcast messages with lower priority.
The Model 390 is Resolve Optics most compact radiation resistant lens. Measuring just 21 x 14mm – the Model 390 is the perfect non browning lens for small sensor cameras operating in high radiation areas. The 5mm focal length fixed focus lens is designed to maintain high clarity up to a total radiation dose of 100,000,000 rad and is optimized for use with ¼-inch image format radiation resistant CCD cameras.
Providing true HD quality images, the Model 390 lens offers a wide field of view and is proven in high radiation nuclear applications including monitoring of hot cells, belt lines and close inspection of baffle bolts.
Rob Watkinson, Resolve Optics sales manager explains “While the Model 390 lens is great for close-up, space limited applications in a high radiation environment it does not compromise on performance. Incorporating specially selected cerium doped glass elements - the Model 390 can capture clear, sharp high-definition images free of the yellow tint inherent in older non browning lenses, with minimum geometric distortion from 400 to 770nm”.
Many organizations rely heavily on accurate indoor environment measurements, but traditionally only large corporations have had the resources to build measurement infrastructures with advanced features such as remote monitoring and easy scalability. Vaisala Echo has been designed to provide the superior benefits of an intelligent indoor measurement infrastructure – but as a built-in feature to selected Vaisala measurement products and solutions.
Vaisala is launching a new solution for industrial indoor and process measurements, Vaisala Echo. Echo connects Vaisala measurement devices and monitoring software to create an intelligent measurement infrastructure. In practice, customers will not buy Echo separately, because it is a built-in feature for Echo-compatible Vaisala measurement products.
“With Echo the days of manually setting up indoor monitoring systems are over. The Echo infrastructure gives you easy, reliable, always-on access to data and alerts from all compatible devices. You pick what you need, based on your measurement, oversight, and reporting needs – and Vaisala guarantees that all instruments talk to the monitoring software, securely, and without glitches,” explains Jarno Mitjonen, Software Product Manager at Vaisala. According to Mitjonen, certain condition-sensitive industries will benefit the most from measurement infrastructures like Echo. These include industrial manufacturing, pharma and laboratories, museums and archives, and indoor and vertical farming. Typically, these sectors will need to measure various parameters like humidity, temperature, CO2, or dew point.
Although large corporations will also benefit from the easy installation and connectivity that Echo brings, Mitjonen believes that the benefits of Echo can best be seen in small and mid-size companies, where maintaining optimal conditions is crucial, but where resources do not allow the creation of the tailor-made systems that are often seen in larger enterprises.
A major benefit of Echo is the easy access to comprehensive reporting – both current and historic. Echo’s reporting on ambient conditions is also real-time and enables notifications and alerts. Remote access to trustworthy and comparable data can help geographically scattered companies compare sites to identify anomalies and take appropriate action to meet corporate targets. This helps reduce costs as it eliminates the need to travel to check and verify the data.
Remote monitoring requires data to be accessible online, so data security was a top priority for Vaisala when designing Echo. All data is encrypted in transit and rest, and secured with digital certificates. Echo also enables remote firmware updates for all connected devices. The result is upgraded security over the whole lifecycle of the measurement infrastructure.
The JUMO DELOS S02 is a compact, reliable pressure transmitter. In addition to a classic analog output, the digital and innovative technologies IO-Link and Single Pair Ethernet (SPE) are available as interface. Therefore the devices can be used in many different industries. The pressure transmitter is used to acquire relative and absolute pressures in liquid and gaseous media. It offers a high degree of process reliability through maximum accuracy and long-term stability. Measuring ranges are from 0.4 to 60 bar relative or 0.4 to 60 bar absolute.
The successor for the current JUMO DELOS SI can be configured via Bluetooth/app or IO-Link. Thanks to the Ethernet-capable (Single Pair Ethernet/SPE) version and the cloud connection, it is used in a wide range of industries (food and beverage, water and wastewater, heating and air conditioning, mechanical and plant engineering, test equipment construction, and laboratories). The JUMO DELOS S02 saves time and costs for users with its user-friendliness. The wide range of versions and interfaces enables a tailor-made selection for the respective area of application.
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