It wasn’t too long ago that hazardous zones and production zones were reasonably well separated. The areas where explosive gases, vapors, or combustible dusts were present tended to stay in their own very specific environments, and the equipment operating in those areas was specified accordingly. Today, however, that distinction is less clear.
As digital transformation increases demand for data from automation systems – driven by new digital innovations such as advanced analytics, AI and expanded connectivity – maintaining system integrity has become a challenge. ABB’s Luis Duran explores how the concept of “separation of concerns” protect the core of the automation system in a cyber-secure way, while enabling new digital value without compromising operational performance.
Online diagnostics and documentation for process automation infrastructure
In many conveyor systems, worn coatings cause unnecessary failures – whether in the food and beverage industry or in material handling. For this purpose, igus offers powder coatings made of high-performance polymers called iglidur coating, which make surfaces significantly more wear-resistant and durable. To make it easier for users to retrofit existing systems, the company now also offers coated plates and wire mesh that can be flexibly cut to size and installed. The range is complemented by IC-05PF, the first PTFE‑free coating, which is intended in particular for applications with high hygiene requirements.
Fast and reliable measurement over wide temperature ranges
Easy-to-maintain solution provides opportunity for massive energy savings
The fertilizer sector is caught in a global paradox between growing food to feed billions and the urgent need to decarbonise. Compressors present a largely overlooked opportunity to reduce lifecycle costs and carbon emissions, while enabling more sustainable production of ammonia. Author: Greg Gedney, Business Development Manager, Industrial Operations, Greene Tweed
Delivering high performance in the UV and visible wavebands for forensic investigation
Polyurethanes (PUR) are found in many products, such as upholstered furniture, foam or insulation materials, flooring, paints and even medical catheter tubes. The production of these high-demand plastics, however, relies on toxic isocyanate. Fraunhofer researchers have now developed an alternative production process using harmless dicarbamate.
Hanna Lundin, product engineer at Emerson, explains in this article how simplified tank monitoring system architectures make it more feasible for companies to implement an automated solution to improve their inventory management, increase safety and efficiency.
In September 2025, a ransomware attack on Collins Aerospace interrupted check-in and boarding systems at major European airports, heavily impacting Heathrow, Brussels, and Berlin. The attackers never breached the airport’s core IT – they didn’t need to. One compromised supplier was enough to paralyze a critical service. Here, Stephan Nobis, business development manager at automation supplier COPA-DATA, discusses why Europe’s critical infrastructure must move from compliance to continuous cybersecurity – or face severe risks.
Integrating Electrical Signature Analysis technology (ESA) in high power drives turns modernization into a digital transformation catalyst for industrial assets. These include motors, pumps, fans, mixers and conveyors operating in hot, toxic or hard-to-access environments, previously regarded as unmonitorable.
The CC-Link Partner Association (CLPA) will mark its 25th anniversary at SPS 2025 in Nuremberg from 25th-27th November. Visitors are invited to live demonstrations on CLPA’s key technology, CC-Link IE TSN and more
AMA Association honors innovative developments in sensor and measurement technology
With the growing complexity of technical plants, demographic shifts in the workforce, and increasingly stringent regulatory requirements, traditional methods of risk assessment are reaching their limits. To meet these challenges, TÜV SÜD has developed a digital approach, called iaHAZOP, that builds on established risk assessment methods and extends them into the digital domain. The process industry now has a tool that redefines the state-of-the-art in technical risk management. Authors: Michael Pfeifer, Senior Expert Adaptive Safety and Alexander Kurdas, Expert for Machinery and Electrical Safety. TÜV Süd
Ethernet-APL enables fast, standardized Ethernet communication down to field level, even in hazardous areas. While the technology simplifies engineering, commissioning, and diagnostics, the real value lies in integrated solutions. With engineered, certified systems tailored to customer needs, operators benefit from reduced complexity, faster deployment, and higher system availability.
Maintaining wind turbines and identifying potential vulnerabilities is expensive and time-consuming, especially when they are located offshore. As a result, rotor blades are often simply replaced, a costly process, when damage is merely suspected. The Fraunhofer Institute for Integrated Circuits IIS, working in concert with the Fraunhofer Institute for Wind Energy Systems IWES, has developed a solution that can be used to identify cracks and breakages inside the blades remotely at an early stage.
Enhanced pump design for higher performance
Maintaining Compliance with the European Union Methane Emissions Reduction 2024/1787 Ruling Requires Quantitative Optical Gas Imaging
The Packaging Competence Centre (PCC) is a joint venture between packaging machinery manufacturer Gerhard Schubert GmbH and Berlin-based packaging consultancy Berndt+Partner Group. The new organisation brings together experts in the fields of regulation, packaging design, materials and automation technology to support manufacturers to develop and implement sustainable packaging.
Industrial processes involving dry foodstuffs or animal feed can quickly create an explosive atmosphere by stirring up dust. Dust explosions present a huge risk not only to human life, but also in terms of destroyed equipment and unplanned production downtimes. Bormann & Neupert by BS&B offers efficient safety systems that effectively nip dust explosions in the bud or minimise their effects.
Multilingual and Open Source: OpenGPT-X research project releases large language model
Elimination of reflections in unfavourable light conditions
Compatible with EtherNet/IP, Modbus TCP and PROFINET protocols
Identification applications in hazardous areas using RFID over a wide operating temperature range
Cleaning systems of industrial large filter systems are often poorly regulated and therefore consume large amounts of expensive compressed air. That´s over now: A new feature of the solenoid valve controller HE 5750 of AXXERON HESCH electronics, allows for an exact setting of the cleaning pressure. We asked the Managing Director, Werner Brandis: How does pre-pressure control work exactly and what are further advantages for the industry?
Steen-Hansen – a Norwegian manufacturer of fouling prevention and net protecting solutions for aquaculture use as well as of specialized industrial paint systems – has not only successfully overcome quality problems with its newly developed antifouling coatings, but also significantly shortened process times, simply by switching its production facilities to state-of-the-art mixing and dispersion technology.
Absolute sterility, optimised processes and lower operating costs – the food industry is challenged to align its production procedures amid these conflicting interests. The measurement technology employed to check individual process parameters plays a decisive role here. WIKA has now opened up a new chapter in pressure instrumentation: an in-line process transmitter with a “dry” measuring cell takes monitoring of this variable in sterile applications to a higher level.
For fluid control applications in sectors such as pharmaceuticals as well as food & beverage production, manufacturers can increase productivity and reduce costs while helping to meet their sustainability objectives by integrating improved control valves. Hydroformed valve bodies for diaphragm valves achieve high strength and light weight. This makes hydroformed valve bodies far more energy efficient compared to forged or cast designs, and the manufacturing process is inherently more sustainable too.
Ethernet APL is a game changer for networking at field level – especially for the process industry. It offers consistent networking with a single protocol, high speeds for cable lengths of up to 1000 metres and intrinsic safety for areas at risk of explosion.
For easier access to diagnostic data of sensors
Today, the majority of consumer goods and everyday items are made from petroleum-based plastics. In Germany alone, around six million tonnes of plastic waste is generated every year. About half of this is mechanically recycled into new materials; the rest is used for energy recovery. The incineration of this waste results in the release of CO2, a greenhouse gas. It is therefore important to keep more plastics in the material cycle for climate and environmental reasons. Eight Fraunhofer Institutes are developing new ideas and processes to significantly improve the mechanical recycling rate of plastics as part of the Waste4Future flagship project.
Under the heading "Forging Tomorrow – Unleashing the Industrial AI Benefits", a panel on the assessment of artificial intelligence by experts from the industry took place at the Emerson Exchange.
Water management is an increasingly important and challenging issue, particularly in light of concerns such as water scarcity. Greater value is thus being placed on disinfection processes. To protect against bacteria, viruses and other harmful organisms, drinking water requires disinfection and hygiene measures. This also applies to the environment in order that lakes and water-based activities can be enjoyed without hesitation. Disinfection processes play a large role in industrial processes as well. In the beverage industry, drinking water flows directly into the products, while surface waters are frequently used as a coolant in other segments such as energy generation.
For accurate, low maintenance measurement online water analysis system
Concrete producer PRO BETON’s lone worker protection equipment has incorporated Wearin's IoT solution, which alerts the control center in the event of an accident and detects falls with unrivalled reliability.
Dr Klaus Endress, CEO of the Endress+Hauser Group for many years and president of the Supervisory Board since 2014, celebrated his 75th birthday. As previously announced, he will end his active involvement in the family-owned business at the end of the year. However, he will remain closely associated with the Group as a shareholder and chairman of the Endress Family Council.
Hermetically-sealed sensors for process control
A digital twin is not only the basis for a holistic view of the system and the individual processes. It is also the basis for automatic routines that react autonomously to changes in the process. It helps applications identify unwanted situations and the countermeasures to be taken often long before the plant comes to a standstill. Predictive maintenance is a key to the efficient operation of a process plant. However, digital processes are not a question of individual products or components, but require the seamless interaction of people and systems.
To date, the KHS coating of wafer-thin, chemically pure glass on the inside wall of PET bottles was primarily applied to improve the quality and shelf life of sensitive soft drinks and juice. VILSA-BRUNNEN Otto Rodekohr GmbH is now the first mineral water bottling plant to profit from Plasmax technology. The family business is consistently investing in its product quality and the long-lasting freshness protection of its premium beverages – and in doing so is setting standards on the market.
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