In this, the first International Process Engineer of 2025, we have several articles looking at AI in industry. The first, Curated crops (page 10), explores the work of Avalo, a company using AI to make cotton that is more resilient to both changes in climate and the production process. As stated in the article, it is typical that 50% of cotton is degraded during the production process, but a more resilient crop strain will help to mitigate this. Another article titled From predictive to prescriptive (page 46) argues that the emergence of agentic AI will see an increase in autonomous decision making in business with real-time adaptability. Dijam Panigrahi COO of GridRaster explains that this type of agentic AI is currently reshaping manufacturing operations. Although the the Industrial Internet of Things (IIoT) has been discussed at length for some time now, improved connectivity and a reduction in the cost of sensors are beginning to make themselves felt. In The new normal (page 6), John Calder technical director from Durapump tells use why he thinks these developments will result in increased deployment of smart pumps throughout industry. As is usual for the magazine, we explore a new area of food processing: this month The perfect ready meal (page 24) looks at the importance of inspection technologies in dried foods. Chemical and process engineers will be gearing up for Hannover Messe at the end of this month. The show will look at industrial technology, with key areas being AI, smart sensors, robotics and the Internet of Things.
Nicola Brittain Editor
Optimising air quality
Curated crops
How AI can make cotton more resilient during production
Next-gen pumps
New pumps from Emerson provide higher flow rates
Biomass actuators
An actuator retrofit from Auma increases efficiency
Interactive smart displays are made for use in industrial settings
The best way of dealing with polluted exhaust air from microchip production
Plastic fantastic
How plastic fans can reduce corrosion in chemical plants
Exploring the role of composites in wide
Exploring the various process industry applications for
How inspection technologies can keep ready meals safe, compliant and tasty
The role of advanced heater technologies in
Extending
smart pumps will go mainstream in
PUBLISHER
Jerry Ramsdale
EDITOR
Nicola Brittain nbrittain@setform.com
STAFF WRITER
Saskia Henn shenn@setform.com
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Shona Hayes shayes@setform.com
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potential when grinding and drying grain
dust testing can reduce the risk of an explosion
value of structured data Boosting safety with data analysis
predictive to prescriptive How agentic AI is reshaping manufacturing operations
the vision capabilities of AI
Messe Advanced technologies explored in this forward looking show
A must attend for chemical process engineers
Setform’s international magazine for engineers is published quarterly and distributed to senior engineers throughout the world. Other titles in the company's portfolio focus on Oil & Gas, Design, Transport, Mining and Power.
New pumps from Emerson provide higher flow rates and greater flexibility
Emerson has released the latest of its next-generation Aventics Series XV
Pneumatic Valve System with new flow rates, configurations, accessories, UL certifications and more. These updates give original equipment manufacturers (OEMs) greater design flexibility and scalability to precisely configure valves when engineering handling systems and automation solutions, according to the company
A US MARKET RELEASE
After launching the Aventics Series XV03 in most world regions last July, Emerson has now released the XV03 valve for US markets, as well as globally released the larger Series XV05 and a bottom-ported version of the XV03. The XV03 provides flow volumes up to 350 litres per minute in normal conditions (NL/min), and the XV05 provides up to 1,000 NL/min.
AVAILABLE WITH UL CERTIFICATIONS
In addition to new flow rates and configurations, Series XV valves are also available with UL certifications
Complete
and more accessories. Both the XV03 and XV05 are designed for compliance with UL429 and UL61010 for quality and safety. New and existing accessories provide greater functionality and include separators, blank stations, pressure supply plates, sandwich pressure supply, and sandwich pressure exhaust. There is also a custom toolbox that contains the most important tools to assemble XV systems.
CONTINUED LAUNCH OF NEW ACCESSORIES
The next phase of the staged XV release will see the continued launch of new accessories as they become available, as well as greater connectivity. Additional fieldbus protocols will be launched throughout 2025, including Powerlink, CanOpen in mid-2025
Series XV valves power machinery and processes at a component level
and AS-I in late 2025. The valve systems currently support Profinet, Ethernet/IP, EtherCAT, Modbus TCP, Profibus DP and IO-Link.
Next-generation Series XV valves use core valve Aventics technology and include metal threads, aluminum base plates and compact dimensions to make integration easier. Complete valve systems are easy to commission with the Aventics online configurator which streamlines design and layout. To reduce lead times for every global region, three Emerson plants are equipped to manufacture orders.
Providing higher flow rates in a compact valve package, Series XV valves enable more efficient and flexible pneumatic system performance while offering products customised for specific markets, including factory automation, automotive and tire, food and packaging applications. Part of a Floor to CloudTM approach, Series XV valves power machinery and processes at a component level, helping manufacturers boost productivity in applications.
ACTUATOR UPGRADE
A new batch of electric actuators now automate previously manually operated valves in a biomass power plant
The Nokianvirran Energia biomass power plant in Finland has significantly increased its degree of automation and thus maximised process efficiency by retrofitting electric actuators made by Auma.
Nokianvirran Energia Oy built a steam cogeneration plant in Nokia in 2016. The plant uses renewable wood-based fuels from the region. It produces process steam for a paper mill and a tyre manufacturing plant, as well as district heating for a large energy company.
Auma experts learned that it took around 30 minutes to start up the boiler from zero to full power, using valves that had to be operated manually. The plant operator’s desire for more automation led to Auma’s multi-turn actuators with intelligent AC 01.2 actuator controls being added
during the overhaul in 2022.
The actuators now enable the system to be started up in just six minutes. Thanks to Profibus interfaces in the actuator controls, the actuators are remotely controlled with Profibus DP from the central control room. In areas subject to heavy vibration or high process
temperatures, the actuator controls were mounted on wall brackets at a distance from the actuators to protect the electronics.
The Auma team took care of the project management, including on-site data acquisition to planning, order processing, installation and commissioning. Thanks to tailor-made adapters the actuators could be perfectly adapted to the existing valves with only minor field modifications.
For more information visit: retrofit.auma.com
Auma actuators in a biomass plant
SCREEN READY
New smart displays will provide engineers with interactive interfaces for use in industrial settings
Display solutions and embedded systems provider, Review Display Systems (RDS) has announced a new range of Android and Linux-based smart displays from a leading supplier of advanced display solutions, DWIN. The innovative display modules have been designed to aid and assist embedded system development software and provide engineers with tools to create user-friendly, interactive graphical user interfaces for industrial, security, healthcare and retail applications, according to the company.
BASED ON ANDROID AND LINUX PLATFORMS
The DWIN smart TFT display range is based on Android and Linux platforms, offering flexibility and scalability for a range of applications. The display modules combine in-plane switching (IPS) TFT LCD displays, built-in projected capacitive (PCap) touchscreens and integrated Rockchip processors, which deliver colourful and bright display images and a fast, responsive user experience, according to the company.
The DWIN Smart TFT display modules offer a range of scalable screen sizes that include compact 5.0-inch modules for portable, mobile devices through to 15.6-inch large format displays for industrial process control panels and signage applications. A range of display resolutions from 800 x 480 pixels (WVGA) up to 1920 x 1080 pixels (FHD) are supported.
Supporting cross-platform development, design engineers can choose between Android or Linux for system development. For applicationrich environments, Android-based displays, enable developers to use familiar programming environments such as Android Studio to build custom applications. Linux can be used for lightweight, secure applications where designers can access open-source Linux software development kits to create tailored applications.
Supporting cross-platform development, design engineers can choose between Android or Linux for system development
PC-BASED AND CUSTOMISABLE
DWIN DGUS is a PC-based, customisable development environment that aims to enable rapid user interface design without the need for extensive coding. The DGUS development system provides a drag-and-drop solution that enables designers of all skill levels to create graphical user interfaces (GUIs) with minimal coding.
Justin Coleman, display business manager, RDS said: “The new DWIN Android and Linux-based smart displays allow developers to bring their ideas to life quickly and efficiently with intelligent display solutions featuring user-friendly programming capabilities. The versatile TFT displays are ideal for design engineers seeking to bring products to market in a timely and efficient manner.
INDUSTRIAL PROCESS CONTROL
For industrial process control, smart systems, med-tech devices, retail signage and more, DWIN Smart TFT display modules can help design engineers create and develop graphics-based interactive systems. The company offers dedicated customer support combined with extensive documentation and example projects, to help designers use the solution while also being able to make use of a wide range of applications.
The DWIN Android and Linux-based smart TFT display range is available immediately from Review Display Systems.
For more information visit: www.review-displays.co.uk
Smart displays for smart applications
CURATED CROPS
Optimising cotton crops with AI will boost resiliency during the production process, as Saskia Henn discovers
By the time crops have landed on kitchen tables, or become infused in cosmetics bottles or woven through shirts, they will have changed hands throughout the supply chain countless times.
Once crops are ready to leave the soil, they begin their journey from the harvester to grain silos, marketers and processing and packaging facilities, with each step along the way bumping up the final price and contributing to emissions.
The common use of pesticides occasionally adds an extra step to the process as well. Some supply chains may include a washing procedure to rid the crops of pesticide residue.
Crops requiring refrigeration may also face further difficulties, depending on the temperature technology used and the distance between facilities.
Overall, a crop’s journey is a tumultuous one, it needs to be part of a substantial yield and, more importantly, comprise high quality cotton to withstand the challenging trip.
CROPS AND CLIMATE CHANGE
It’s no secret that climate change is threatening crop quality. At the mercy of increasingly volatile conditions, tomatoes bruise and shrivel under the sun, cotton’s fibrous elasticity weakens without water and the biodiversity loss from rubber plantations becomes less and less justifiable.
Climate change’s rapid encroachment also means that currently unproblematic locations could look completely different very soon, potentially no longer able to support the same crops as before.
To preserve the reliability of crop supply chains, the crops themselves must be able to withstand increasingly demanding and unpredictable conditions so they can survive the many steps from the field to the consumers.
But what if there was a way to increase crop quality as well as simultaneously optimise supply chain steps? That’s where plant biology company Avalo AI comes in.
ABOUT AVALO
Avalo AI’s machine learning capabilities identify the genetic components of desirable crop phenotypes and amplify them through selective breeding.
Built on the fundamental practice of crossbreeding, the company uses datadriven insights to enable more precise selections by breeders more quickly. Since the algorithm can predict the performance of a seed without needing to grow it, the process of obtaining desirable traits such as heat and drought tolerance is accelerated by up to 70%.
“The problems of farming are universal in that, just being in the industry that they are in, they’re getting squeezed from both sides,” says Avalo co-founder and CEO Brendan Collins.
With input costs rising while customers seek cheaper end products, farmers are experiencing a compression that could affect every aspect of the supply chain.
Farmers are experiencing a compression that could affect every aspect of the supply chain
Collins and co-founder and CSO Mariano Alvarez created Avalo in a bid to outrace climate change by breeding crops for future environments. Optimisation of the supply chain is a byproduct of the work.
Crop breeding requires a two-tothree-year development cycle, so focussing on what an environment may be like in 10 or 20 years enables proactive farming that shields crops from immediate environmental damages as well as transportation, processing and packaging challenges.
Avalo begins the machine learning process by choosing 500 seeds representing the most genetic diversity among all the crops in the world. The phenotypes, genetic information and environmental data are all added to the algorithm, which helps to determine which combination of genetic markers could be best suited for a particular desired outcome.
“If you’re able to measure all these different traits and find a genetic basis with them, you can get potentially really interesting outcomes owing to the AI component,” says Collins.
Indeed, there are many aspects of crop growth that can be explored with the algorithm. So far, this technology has led to the production of heatresistant tomatoes, non-tropical sugar cane, resilient cotton and pesticide-free broccoli that matures in only 37 days.
AVALO AND THE SUPPLY CHAIN
Crops with this level of protection are better able to survive the supply chain,
especially if that supply chain is highly streamlined, according to the company.
“We’ve explored the different places within the supply chain,” says Collins. “One thing that we’re trying to do is work with the mills, garment manufacturers and brands to collect
data on how fibres react to each step in the process – this knowledge will help us create a resilient product that can better withstand the industrial process.
Cotton density, for example, decreases when touched repeatedly with a physical saw blade while it is being purified and woven into the final garment.
“By the time cotton has passed all the industrial steps to become a t-shirt, more than 50% of the original cotton will have been degraded,” says Collins.
Optimising a crop using AI could lead to farmers using less fertiliser, saving them money or lowering prices for end customers. The prices would also depend on factors, such as the supply chain being used and how competitively farmers sell their crops.
While there are many potential outcomes for introducing a certain level of flexibility into the supply chain, one thing is certain: Breeding resilience is becoming easier.
Avalo chose the 500 seeds that would provide most genetic diversity
Optimising a crop using AI could lead to farmers using less fertiliser
SIZE MATTERS
With a projected value of US$145 billion by 2030, the large diameter pipe market is poised for significant growth, driven by rising investments in water management and infrastructure renewal. However, the applications of wide diameter tubes extend beyond these projects.
International Process Engineer caught up with Lauri Turunen, product manager for tubes at pultruded and pull-wound composites specialist Exel Composites, to discuss the versatility of wide tubes; how new materials are outperforming traditional ones; and where tubes are heading in the future.
Wide diameter tubes are defined as those with a diameter greater than 100mm; such tubes are designed to handle a variety of industrial applications owing to their robust size and strength. They are also engineered to support substantial loads and resist external forces, making them crucial for projects that demand structural integrity.
Lauri Turunen, product manager for tubes at pultruded and pull-wound composites specialist, Exel Composites
What role do composites play in wide diameter tube development?
Composite tubes have been in use for decades as they provide benefits to many industries. They are used, for example, in telescopic masts and antennas, as well as transportation and military applications. In the marine industry, big composite tubes help provide protection against harsh environments.
Lauri said: “Composite manufacturing technologies like pultrusion and pull-winding have been developed to suit the larger diameter tube production by scaling up the machinery and improving the process in general. This has led to more efficient and faster production”.
USED IN A VARIETY OF SECTORS
In the construction sector, wide diameter tubes are used as structural supports, utility poles, and fender systems in marina construction for example. Their load-bearing capacity ensures stability in structural applications and supports high-
voltage equipment while withstanding environmental conditions such as heavy rain and strong winds and currents. In the oil and gas industry, these tubes are used as pipelines, effectively managing high pressure and flow rates associated with transporting fluids over long distances. This enables the safe and efficient delivery of oil, gas, and other liquids.
Additionally, wide diameter tubes play a vital role in robotics and military applications. They are used in large-scale masts and antennas, providing the strength and stability required for long-distance communication and surveillance. For mobile towers and other adjustable equipment, they serve as telescoping poles, maintaining structural integrity when extending or retracting.
NATURAL CHARACTERISTICS ARE BENEFICIAL
As Lauri explained, the natural characteristics of large composite
tubes (lightweight, strong, nonrotting and corrosion resistant) mean the market is capturing area from traditional materials. He said: “The expanding market initiates more development towards the process, materials and technologies themselves. This leads to even better products with higher efficiency bringing the production costs down, too.”
The tubes are used for multiple applications such as machine parts (robots) or parts of the production line (rollers for films/paper) in the process manufacturing industry. There are countless possibilities for the use of lightweight and strong composites.
WHY PULTRUDED COMPOSITES?
Composite materials, such as carbon fiber and fiberglass, provide substantial benefits over traditional materials for wide-diameter tubes, particularly when manufactured using the pultrusion method.
This continuous production process involves drawing reinforcing fibers, such as glass or carbon, through
a resin matrix and curing them in a heated die to create lightweight, durable profiles with exceptional precision. Pultrusion significantly reduces material waste and ensures consistent quality, making it an efficient and reliable solution for producing high-performance tubes.
THE BENEFITS OF DENSITY
For instance, glass fiber has a density of around 2.5 g/cm3 , approximately 75 per cent less than steel at 7.85g/cm3, despite possessing superior strength. Such low density gives composites an edge over other materials. Although glass fiber may come at a higher material cost, its lighter weight makes it quicker to install and requires few personnel, ultimately lowering labour costs and speeding up project timelines.
FUTURE APPLICATIONS
The role of wide diameter composite tubes is set to expand significantly as demand for sustainable infrastructure solutions grows. Their high strength-
to-weight ratio makes them ideal for applications such as pedestrian bridge supports or in the rehabilitation of existing structures, offering a durable and low-maintenance alternative to traditional materials.
THE ROBOTICS MARKET
In robotics, the use of wide diameter tubes in large-scale manipulators is expected to increase, with composites enabling the creation of lightweight yet robust structures. Similarly, in aerospace, these tubes could become integral to support structures for aircraft and spacecraft, aiding in weight reduction while maintaining strength.
As engineering embraces these innovations, the strength and durability of wide diameter composite tubes make them a ‘must have’ across such diverse industries as water infrastructure, oil and gas and modern aerospace. For
OPTIMISING AIR QUALITY
The production of microchips generates large volumes of polluted exhaust air, this article explores how the air is best treated
Many technical processes generate chemically aggressive and corrosive exhaust air streams that may only be released into the atmosphere in a purified state for environmental protection reasons. In many countries, legislation regulates the maximum permissible pollutant limits. Exhaust air purification systems made of plastic are used to treat chemically aggressive exhaust air and gases, as these materials are highly resistant to corrosion.
EXHAUST GASES WHEN PRODUCING MICROCHIPS
Such exhaust gases are also produced during the production of microchips in the semiconductor industry. Microchips are installed in a large number of electrical devices. They are used in computers and smartphones, for example, and therefore form the basis of modern digitalisation. The production of microchips generates large volume flows of polluted exhaust air. The exhaust air contaminated with acid and
ammonia vapours is cleaned with exhaust air scrubbers.
AN EXHAUST AIR PURIFICATION SYSTEM FOR THE SEMICONDUCTOR INDUSTRY
An existing production facility for microchips has been expanded. The investment for a new production building amounts to several hundred million euros and several hundred new jobs are to be created.
The exhaust air flows are collected separately and fed into the control centre via a coated pipe network. A total of up to 100,000 m3/h of acidic and 100,000 m3/h of ammoniacontaining exhaust air must be purified. In addition to purification and compliance with the applicable limit values, energy is also to be recovered from the exhaust air flows. The volume flow is variable; for redundancy reasons, the volume flow is divided between three exhaust air scrubbers. Depending on the operating point, the scrubbers can be switched on or off.
EXECUTION OF THE TREATMENT
The exhaust air is treated by horizontal packed-bed scrubbers with integrated heat exchangers for heat recovery. All components in contact with the medium are made of corrosion-resistant plastic on both the gas and liquid sides.
Exhaust air purification is achieved by absorbing the pollutants from the gas phase into the water phase. This requires the largest possible contact surface. The surface area is achieved by using special packing with a high specific surface area.
The air flow is channelled horizontally through the packing. A circulation pump continuously sprays washing liquid from the reservoir above the filler pack. It is distributed via nozzle lances. The washing liquid flows over the tower packing and collects in the lower part of the scrubber.
Exhaust air scrubber made of plastics with integrated heat exchanger for a volume flow of 30,000 m3/h
In order to set the optimum pH value of the washing liquid for the cleaning process, a complete pH value regulation and chemical dosing system is installed. This means that the pollutants are not only dissolved in the water, but are also chemically neutralised. The level in the scrubber is kept constant via a level measurement. Evaporation losses and the absorption of pollutants from the air increase the salt concentration in the scrubbing liquid. To avoid unacceptably high concentrations, the conductivity in the liquid is measured. If a specified value is exceeded, water is removed from the system via the waste water valve. A droplet separator is installed after the cleaning stage to separate the entrained liquid droplets.
FUTURE
PLASTIC FANS
Exploring the advantages of plastic fans for mitigating chemically aggressive exhaust air and gases
Plastic fans/blowers for industry, laboratories and buildings are used in a variety of applications where corrosion resistance, chemical resistance and durability are particularly important. They are primarily used in areas where aggressive or corrosive gases need to be extracted or transported; such as chemical and pharmaceutical plants, in electroplating, in wastewater treatment plants, in laboratories or in the semiconductor industry.
Here, the corrosive effect on metallic components is so strong that materials such as stainless steel or aluminium can quickly be damaged.
ADVANTAGES OF PLASTIC FANS
The biggest advantage of plastic fans is their corrosion resistance. Fans made from thermoplastics such as polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC) or polyvinylidene sulphide (PVDF) are extremely resistant to aggressive chemicals and moisture. This makes them ideal for use in environments where corrosive gases such as acid vapours, alkalis or salts are present, this would severely corrode and damage traditional metal fans.
Another advantage is the lower weight of plastic fans compared with fans made of steel or aluminium. This makes installation easier and reduces
the structural requirements for the building or construction in which the fans are installed. In addition, the lower weight leads to reduced operating costs as the fans tend to be more energy efficient, especially if speed changes are required to match the desired operating point (e.g. due to increasing filter losses).
Plastic fans are also highly flexible, increasing their adaptability to special requirements. Different types of plastic can be selected depending on the specific application to ensure the best possible protection against the respective chemical influences.
Another plus point is the electrical insulation properties of most plastics, which can be an advantage in certain applications. In the case of explosive exhaust gases, however, they must be electrostatically dissipative, which can be achieved by using PPs-el with additives such as carbon black particles in the plastic. In addition, plastic fans often have a longer service life due to their corrosion resistance.
COLASIT’S RANGE
Colasit offers a wide range of plastic fans (also in ATEX version) developed for both standard applications and special customised requirements. Colasit fans cover a wide range of volume flows (V) and pressure ranges (p). In terms of volume flows, Colasit plastic fans can handle air volumes
from a few hundred cubic metres per hour to over a hundred thousand cubic metres per hour and more. The pressure ranges also vary greatly and cover both low- and high-pressure requirements up to over 7,000 Pa.
The product range extends from the smallest standard fans (from a tube diameter of Ø 75 mm) and medium sizes up to Ø 400 mm to large fans with tube or duct connections up to 1,250 mm, which have been developed for industrial applications with high air flow rates and high-pressure requirements. Colasit offers both centrifugal and axial flow fans to meet the specific requirements of different applications. In addition, Colasit roof fans are used on the roofs of end customers to transport the exhaust air out of the building.
CONCLUSION
Colasit plastic fans are indispensable in many industries, especially where aggressive, corrosive and explosive gases need to be transported or extracted. Their excellent corrosion resistance, low weight, long service life, flexibility in material selection and use for ATEX applications make them an ideal solution for demanding environments.
For more information visit: www.colasit.com/en/products
Colasit fans cover a wide range of volume flows and pressures
FIGHTING FIRE
An in-depth look at the history of flame detection in high-risk environments
HD vision-based flame detectors perform in high-risk environments
Fire detection has advanced from basic heat and smoke sensors to modern visual flame detection systems. Developed in Scotland and improved over 30 years, today’s HD visionbased flame detectors from Micropack are designed to perform in high-risk environments like FPSOs, refineries, and chemical plants.
As industries grow, ensuring early and accurate fire detection remains crucial for safety and operational efficiency. Traditional fire detection methods often lead to false alarms or missed real fires. Visual flame detection changed this by providing a smarter, more targeted solution. Just like Tesla’s self-driving technology detects obstacles; and iPhones use facial recognition to unlock securely, Micropack’s flame detectors use vision-based technology to identify flames while filtering out false alarms.
This intelligent flame detection system cuts false alarms and integrates seamlessly with industrial fire and gas systems.
EARLY FLAME DETECTION METHODS
Fire detection originally relied on heat, smoke, and infrared (IR) sensors. These methods had major drawbacks:
Heat sensors: Too slow to detect flames early.
Smoke detectors: Only work in enclosed areas with slow-burning fires.
IR and IR3 flame detectors: Prone to false alarms from hot surfaces and reflected radiation.
IR detectors improved detection times but couldn’t distinguish between real fires and background heat, leading to frequent false alarms. This created demand for a smarter detection approach.
THE BIRTH OF VISUAL FLAME DETECTION
Visual flame detection (VFD) changed fire safety by using image processing to identify flame patterns based on movement, shape, and spectral properties.
In 1996, Micropack introduced the FDS101, the world’s first visual flame detector, ‘setting the foundation for today’s advanced systems. This marked a major shift from heat-based detection to a vision-based approach, reducing false alarms while maintaining high sensitivity to real fires.
The FDS301 further improved accuracy by using real-time video processing, allowing operators to visually confirm fire alarms. These early innovations paved the way for today’s HD vision-based flame detectors.
CONTRIBUTING TO VISUAL FLAME DETECTION
Micropack has continuously refined its flame detection technology, making it more reliable and consistent in challenging environments. Key developments include:
MAVIS (Machine Vision Algorithm for Intelligent Sensing): A highly developed vision algorithm that detects flames while filtering out false alarms from flare reflections, hot exhausts, and process heat sources.
Event recording and verification: Live video footage lets operators instantly verify alarms, reducing unnecessary shutdowns and improving response times.
Seamless integration: Visual flame detectors now integrate with fire and gas safety systems like the Consilium SMIG System, providing real-time insights into fire risk areas.
OVERCOMING FALSE ALARM CHALLENGES ON FPSOS
Micropack’s flame detection technology was born out of the North Sea oil and gas industry, where tough conditions demanded smarter solutions.
One of the biggest challenges on Floating Production Storage and Offloading (FPSO) vessels was false alarms caused by flare reflections, engine exhaust, and process equipment heat. Traditional IR detectors struggled in these conditions, leading to costly shutdowns and disruptions.
MAVIS was built to solve this problem, ensuring accurate detection even in extreme environments. By analysing flame movement and targeted spectral characteristics, MAVIS enables FPSOs and offshore platforms to detect real fires without false alarms. The result is a more stable, cost-effective, and trusted fire detection system.
A SCOTTISH INNOVATION WITH GLOBAL REACH
Developed in Scotland, Micropack’s flame detection technology is now used worldwide in offshore platforms, refineries, chemical plants, and highrisk industries. Its ability to detect
real fires while ignoring false alarms has made it the preferred choice in Europe, North America, Asia, and the Middle East.
Micropack’s detectors carry globally recognised performance and hazardous area approvals, including:
FM3260 – Flame detection performance standard.
EN54-10 – Fire detection and alarm systems.
ATEX & IECEx – Hazardous area certifications.
SIL 2 – Safety certification for critical safety applications.
These approvals ensure Micropack’s flame detectors meet the highest industry standards.
THE MODERN ERA OF MAVIS-POWERED FLAME DETECTION
Today’s visual flame detection systems use MAVIS, a vision-based algorithm developed through decades of realworld testing. Unlike traditional sensors that react to heat, MAVIS recognises the visual characteristics of real flames, making detection more accurate across a wide range of industries.
Modern detectors also integrate live video into the Consilium SMIG System, enhancing fire safety with real-time monitoring. This is the same principle used in self-driving cars to detect obstacles and in smartphones for facial recognition— Micropack’s visual flame detectors apply that same precision to fire detection, ensuring accuracy in complex environments. Operators can verify incidents instantly, reducing response times and lowering costs by preventing unnecessary shutdowns.
CONCLUSION
The evolution of visual flame detection, from black and white cameras to HD vision-based flame detectors, has transformed industrial fire safety. Visual flame detection has transformed industrial fire safety by offering reliable detection, fewer false alarms, and seamless integration with fire and gas systems.
Backed by globally recognised certifications, modern visual flame detection ensures fast, accurate, and dependable fire detection in critical environments.
As industries evolve, fire detection technology must continue advancing to meet new challenges, providing industrial operators with reliable and cost-effective solutions.
TOP TESTING
Rigorous
testing of
this advanced field instrument proves improved accuracy
The rapid evolution of Industry 4.0 has placed an increasing demand on advanced automation and smart technologies to optimise industrial processes. A key enabler of this transformation is the integration of intelligent field instruments that enhance operational efficiency and reliability. A comprehensive evaluation of the Focus-1 device by Nobian underscores the critical role of precision and efficiency in modern industry.
THE ROLE OF FOCUS-1 IN INDUSTRIAL OPTIMISATION
The Focus-1 device streamlines process control by combining multiple functionalities, such as flow, pressure, and temperature measurements, into a single, compact unit. This integration reduces hardware complexity while improving real-time monitoring capabilities. As industrial processes become increasingly data-driven, the ability of a device to provide accurate and consistent measurements is crucial for operational stability. The elimination of multiple separate sensors not only reduces installation costs but also simplifies maintenance and calibration procedures.
Industry 4.0 relies heavily on connectivity and real-time data access for predictive maintenance and process optimisation. Focus-1’s integrated approach provides a unified data stream, allowing industrial operators to make informed decisions quickly. Furthermore, as energy efficiency becomes a primary concern, the device supports sustainable practices by reducing energy wastage and unnecessary resource consumption.
TESTING FOR RELIABILITY
Nobian undertook an extensive testing programme to assess the
The Focus-1 device can function in extreme conditions, helping to prevent disruption
accuracy, responsiveness, and longterm reliability of Focus-1 in realworld industrial environments. The evaluation focused on:
Measurement accuracy: Ensuring that data collected by the device aligns with industry standards for precision, reducing process inefficiencies.
Efficiency optimisation: Analysing how the device contributes to energy savings and process efficiency. System integration: Testing compatibility with existing industrial control systems for seamless connectivity. Environmental resilience: Assessing performance under varying temperature and pressure conditions to confirm reliability in demanding industrial settings.
FINDINGS AND INDUSTRIAL IMPLICATIONS
The testing revealed that Focus-1 consistently delivered high measurement accuracy, reducing variability in process control. By consolidating multiple measurement functions, the device demonstrated efficiency gains, minimising the need for additional instrumentation and reducing maintenance costs.
Furthermore, its seamless integration with digital industrial networks facilitated better process visibility and data-driven decision-making. Additionally, the ability to function in extreme conditions ensures that industrial operations can continue without disruption, even in challenging environments. This resilience is critical for industries such as chemical processing, energy production, and water treatment, where precise measurements and reliability are essential.
ADVANCING INDUSTRY 4.0 THROUGH SMART TECHNOLOGIES
The successful evaluation of Focus-1 reaffirms the importance of smart instrumentation in achieving Industry 4.0 goals. As industries continue to embrace automation, devices like Focus-1 will play a pivotal role in enhancing digital transformation initiatives.
Future advancements in intelligent field instrumentation may include artificial intelligence for predictive analytics, further improving process optimisation. Such developments could enable industries to shift from reactive to proactive maintenance, minimising downtime and enhancing productivity.
From
left
to
right: The SpiraMAG DN100 and the Unimass E030-50
FINDING THE FLOW
James Lees from UK Flowtechnik explores the various process industry applications for flowmeters
Non-invasive flowmeters offer a host of advantages, making them an essential tool for numerous industries requiring precise fluid measurement. Alongside traditional contact style flowmeters such as gear (circular, helical and oval), axial turbine, pelton wheel, and variable area flowmeters, there are magnetic inductive flowmeters. These non-invasive technologies deliver accuracy and reliability, addressing the challenges of modern industrial applications.
CORIOLIS FLOWMETERS IN THE POLYURETHANE FOAM INDUSTRY
In the polyurethane foam industry, Coriolis flowmeters have become indispensable for the precise measurement of raw materials, specifically isocyanates and polyols. These components are critical to foam production, where consistent quality, density, and performance are paramount. Coriolis flowmeters excel in this application by providing instant mass flow measurements that are unaffected by variations in temperature, pressure, or fluid viscosity. This capability ensures accurate chemical dosing and maintains the correct stoichiometric ratio in foam formulations. Furthermore, the ability of these flowmeters to measure both mass flow and density enables realtime monitoring and adjustments, significantly enhancing product quality and minimising waste.
Coriolis flowmeters are particularly well suited for polyurethane production owing to their ability to handle a wide range of fluids, including viscous and abrasive substances. The inherent accuracy and reliability of these flowmeters contribute to superior process control, improved efficiency, and reduced material costs. Manufacturers benefit from consistent foam quality while meeting safety and regulatory requirements, underscoring the transformative impact of this technology on the industry.
MAGNETIC INDUCTIVE FLOWMETERS IN THE BEVERAGE INDUSTRY
Similarly, magnetic inductive flowmeters (often referred to as mag meters), have proven invaluable in the beverage industry. These flowmeters offer precise, non-intrusive measurement of conductive fluids such as water, juices, and soft drinks. Their utility extends to critical processes like mixing, batching, and filling, where precision is key. Mag meters operate using Faraday’s Law of Induction, generating a magnetic field that induces a voltage as the conductive liquid flows through it. This voltage correlates directly to the flow rate, ensuring highly accurate and repeatable measurements.
One of the primary advantages of mag meters is their design, which eliminates moving parts. This reduces maintenance requirements and the risk of contamination, a crucial
consideration in food and beverage production, where hygiene and safety are non-negotiable. Additionally, mag meters cause minimal pressure drop, maintaining consistent flow rates and optimising process efficiency. Their ability to handle varying fluid viscosities and temperatures makes them versatile enough for a wide range of beverages, including carbonated drinks, fruit juices, and syrups. These features make magnetic fl owmeters indispensable for ensuring product quality and streamlining production processes in the beverage sector.
CONCLUSION
The applications of non-invasive fl owmeter technologies extend far beyond these two examples, demonstrating their versatility and value across various industries. By adopting Coriolis and magnetic inductive fl owmeters, businesses can achieve improved accuracy, efficiency, and reliability while reducing costs and ensuring compliance with stringent industry standards. James says: “UK Flowtechnik remains committed to providing cutting edge solutions that empower our clients to optimise their operations and maintain a competitive edge in their respective markets.”
For more information visit: www.ukflowtechnik.com
HAMPRO® HIGH-PRESSURE PROCESS TECHNOLOGY
The high-pressure pumps of the HAMPRO® series are used in the Oil and Gas Industries to pump a very wide range of fluids, meet the stringent requirements of the relevant safety and reliability regulations and are characterized by a robust design and careful use of resources.
Our experienced team of experts will be happy to help configure the perfect solution for your individual application.
RECIPROCATING PUMPS TO API 674
- Glycol pumps - Leak test pumps
- Methanol pumps
- Produced water injection pumps
- Sea water injection pumps
Pressure: 50 – 4000 bar
Flow rate: 0,1 – 256 m³/h
Hammelmann GmbH
Carl-Zeiss-Straße 6-8
(0) 25 22 / 76 - 0 pp@hammelmann.de
D-59302 Oelde www.hammelmann-process.com
The X12 Mettler Toledo x-ray inspection system can identify contamination in food produce
THE PERFECT READY MEAL
Miriam
Krechlok
from Mettler-Toledo explains how inspection technologies can keep ready meals safe, compliant and tasty
Ready meals today offer more than just convenience. From dehydrated noodles to sauced pasta dishes, such dishes have become a sophisticated product category. However, each type of ready meal poses unique production challenges.
THE IMPORTANCE OF INSPECTION TECHNOLOGIES
Inspection technologies, such as metal detection, x-ray inspection, vision inspection and checkweighing are crucial for maintaining the integrity and safety of ready meals. These technologies help detect physical contaminants, achieve proper labelling and confirm consistent portion sizes.
CHALLENGES IN DRY READY MEAL PRODUCTION
Dry ready meals, such as instant noodles, dehydrated soups and rice mixes, present specific challenges. One of the primary issues is the generation of dust and fine particles during production. These particles can interfere with inspection systems and obscure contaminants, making detection difficult. Once
the ingredients are fried and dried, maintaining hygiene becomes critical, and confirming packaging integrity is essential to prevent moisture from compromising product freshness.
EXAMPLE IN ACTION: INSTANT NOODLES
Take the production of instant noodles as an example. This popular meal involves several key steps, each presenting its own challenges:
• Raw material inspection: The process begins with inspecting incoming raw materials, such as flour and oil. Advanced metal detection systems are employed early in the process to screen these ingredients for ferrous and non-ferrous metals and stainless steel, capturing contaminants before they can enter the production line.
• Mitigating explosion risk: Inspection of dusty, powdered products such as flour carries a potential explosion risk. If using a metal detection system at this stage, it is important to select one with a suitable design that complies with explosion prevention regulations such as ATEX / IECeX.
• Advanced detection technology: To combat product issues, advanced metal detection technologies, such as Multi-Simultaneous Frequency systems, are often employed. These systems use multiple detection frequencies simultaneously, allowing the equipment to distinguish between the product and actual contaminants.
The frying and drying stages of making dry noodles will introduce additional contamination risks from oil and fine particles. Oil can trap contaminants or coat foreign objects, complicating detection. Fine particles can obscure contaminants, particularly in dusty environments. To address these risks, metal detection systems are employed post-frying to identify any remaining foreign bodies. Checkweighers are also utilised to confirm that portion sizes remain consistent, further supporting product quality and reducing waste.
PACKAGING AND FINAL INSPECTION
During the packaging stage, x-ray technology is crucial for scanning for contaminants such as glass or
plastic that may have entered the process. Agglomerates can also pose a challenge, especially in dried products where flavouring or seasoning can clump together. Advanced x-ray technology is required to differentiate between harmless clumps of ingredients and actual contaminants.
WET READY MEALS: TACKLING CONTAMINATION AND PACKAGING INTEGRITY
Wet ready meals, which include soups, stews, sauced pasta dishes and curries, also present unique challenges owing to the differently constituted elements: a high liquid
content and dense ingredients. These meals are often highly processed and this further increases the risk of contamination.
EXAMPLE IN ACTION: SOUP PRODUCTION
In the production of soups, the process begins with inspecting raw ingredients such as vegetables, meats, grains and other ingredients. Since soups are considered a pumped food, they contain chunks of other foods that are essential and cannot be sieved out. Metal detection and x-ray systems are employed to screen for foreign bodies in these ingredients before they are mixed and processed.
FILLING PROCESS AND PACKAGING INTEGRITY
During the filling stage advanced inspection technologies like x-ray systems come into play. These systems are highly effective at detecting contaminants through complex packaging materials.
Weight control systems are also critical during this stage, as they verify that each container has the correct quantity of food. Imbalance in portions could lead to inconsistent product quality and non-compliance with weights and measures legislation, making checkweighers essential.
The integrity of packaging is also important for wet products, as any leakage can lead to spoilage or bacterial growth. X-ray systems help identify weak spots in the packaging that may result in leaks.
All process industries face mounting pressure to improve both operational efficiency and environmental performance. While electrification is a key component of this transformation, it is only one part of the solution. The real potential for achieving higher efficiency and sustainability lies in the use of advanced heater technologies in an integrated thermal loop, as Volker Metzger, Applied Thermal Expert at industrial technology company Watlow, explains. This is particularly true for oil and gas.
Electrification is no longer a mere trend but an imperative. Industries are under pressure from regulators, consumers and shareholders to decarbonise, and electric heating systems play a critical role in achieving this transformation.
LEVERAGING ADVANCED HEATER TECHNOLOGY
heaters, which handle the high-power demands of industrial applications while offering improved efficiency and safety. Operating at up to 7,200 volts, electric heaters reduce the need for large step-down transformers and minimise the heat generated by cabling, leading to lower installation and maintenance costs.
TRUST IN THE THERMAL LOOP
Continuous helical flow technology has revolutionised the efficiency and reliability of electric heaters. Traditional heating systems often suffer from dead zones, leading to hotspots, coking and fouling. These issues reduce efficiency and increase maintenance needs, causing costly operational disruptions. Continuous helical flow technology mitigates these challenges by ensuring uniform temperature distribution across the heating surface, significantly reducing fouling and extending the heater’s operational life.
Another key development is the use of medium voltage electric
However, the true potential of advanced heater technology is realised when it is integrated into a comprehensive thermal loop that includes not only heaters but also sensors, power management systems and data analytics. This system-wide approach enables companies to fine-tune their operations with unprecedented precision, ensuring tighter temperature control, optimised energy use and long-term sustainability. When integrated with proportionalintegral-derivative (PID) controllers and real-time data analytics, modern electric heating systems such as medium voltage solutions, provide superior performance in high-temperature processes. These solutions offer advantages over traditional gas-fired systems, such as greater temperature control, reduced energy consumption and minimised maintenance costs.
PREDICTIVE AND DATA-DRIVEN
The full advantages of electric heaters cannot be achieved without integration of predictive maintenance systems. By continuously monitoring system performance through real-time data analytics, operators can detect early signs of system wear, such as temperature drifts or anomalies, before they escalate into major issues. This approach helps reduce unplanned downtime, extend equipment life and lower maintenance costs.
Incorporating digitalisation into the thermal loop also allows for data-driven optimisation, enabling companies to reduce energy consumption by adjusting power usage based on realtime performance data. By analysing process trends and using predictive insights, companies can optimise energy use, providing a significant competitive advantage in an era where energy efficiency is paramount.
Electrification plays a pivotal role in improving efficiency and sustainability in the oil and gas industry. However, the real transformation comes from the integration of advanced heater technologies within a comprehensive and electrified thermal loop.
Innovations like continuous helical flow technology, medium voltage electric heaters and predictive maintenance systems enable companies to achieve greater efficiency, lower emissions and enhanced reliability.
A
TANK
TENACITY TANK
Storage tanks are capitalintensive installations in industries such as energy, chemicals, water treatment, and food and beverage production. However, because of their contents and environmental exposure to humidity, salt-laden air, and/or extreme weather, deterioration occurs, maintenance costs rise, and the ecological environment or local communities may be at risk. Protective measures are required in order to extend tank service life and ensure operational reliability.
Recent developments in coating and wrap technologies can mitigate these risks and reduce maintenance expenditure. From internal linings to external coatings, thermal insulation, and cathodic protection, modern innovations have restructured the ways industries protect their valuable assets.
INTERNAL LINERS: PROTECTION AGAINST CORROSION
Internal corrosion remains one of the most important risks to storage tanks, especially to those used for products with corrosive or reactive natures. An example could be number 6 fuel oil, a very dense and viscous liquid that can slowly deteriorate tank walls without proper protection. Advanced internal lining technologies, such as US Coatings GripLine 6700, offer
Extending asset life: Exploring advanced solutions for storage tanks
robust chemical resistance, protect the interior from corrosive agents, and dramatically reduce maintenance costs.
These modern linings are formulated to resist aggressive environments, while optional enhancements like glass flake can provide added strength. These highperformance solutions minimise operational downtime and extend the service life of tanks. In certain cases, advanced linings can increase inspection intervals by five years or more, reducing costs while improving long-term asset integrity.
EXTERNAL COATINGS: PROTECTION AGAINST ENVIRONMENTAL FACTORS
External tank surfaces are very sensitive to the environmental effects caused by temperature changes, high humidity, and exposure to corrosive elements like salt. If not treated, such conditions can bring about a loss of structural integrity, increase in maintenance, and safety concerns. Coatings present a formidable barrier to these elements. Highadhesion primers and advanced anticorrosion coatings together protect storage tanks against moisture, contaminants, and UV exposure, even at elevated temperatures. Formulated for the most extreme environments, these coatings serve dual purposes:
they protect the storage tanks while maintaining their appearance over time, minimising the need for frequent recoating and expensive repairs.
THERMAL INSULATING COATINGS: MAINTAINING PROCESS STABILITY
Temperature-sensitive materials are commonly stored in storage tanks that need to maintain consistent internal temperatures. Traditional methods of insulation, such as cladding and wraps, are usually heavy, prone to moisture intrusion, and require periodic maintenance.
New solutions, like Mascoat Industrial coatings, have proven much more effective and long-lasting. These coatings, applied directly to the surface of a tank, provide a continuous insulation layer that greatly reduces thermal loss or heat gain. The thickness can be adjusted for a wide range of applications, including personnel protection, condensation prevention, energy retention, prevention of flash cooling, or solar load reduction.
LINEAR ANODES FOR CATHODIC PROTECTION
Above-ground storage tanks are susceptible to floor corrosion owing to the contact of the tank floors with soil or concrete foundations. Over time,
DELIVERING THE DATA THAT ENERGIZES OUR WORLD
TEMPERATURE MEASUREMENT TECHNOLOGIES FOR THE ENERGY INDUSTRY SECTOR.
electrochemical reactions between the steel floor and its foundation can lead to corrosion failures, which cause leaks, structural damage, and costly repairs.
However, to eliminate such risks, Anodeflex offers an ICCP system tailored for this purpose: the LinearFlex system. The LinearFlex is installed in a concentric ring pattern under the tank floor to provide uniform current distribution for corrosion protection, whether it is for a new construction, floor replacement, or retrofitted CP system.
Unlike traditional cathodic protection methods that are largely field-assembled, LinearFlex is
factory-assembled and pre-tested for ease of installation and reliability. This system effectively prevents floor corrosion, thus prolonging AST life while reducing maintenance costs over an extended period.
WRAPPING SYSTEMS: A NEW APPROACH
One of the major challenges asset owners face is corrosion on tank roofs and chimes due to environmental exposure, water ingress, and temperature fluctuations. This all combines in the degradation of materials, raising maintenance needs and safety concerns. Traditional coatings have
a lot of surface preparation and require frequent touch-ups; hence, maintenance is expensive and time-consuming.
The Stopaq tank protection system combines Wrappingband EZ with 4200 Filler to create a seamless, selfhealing corrosion barrier. Wrapband EZ is an amorphous polymer material that flows together upon application, forming a flexible, watertight seal. The product accommodates tank movement without aging or disbonding for long-term durability. The 4200 Filler is applied for use for the fi lling of tank chimes to eliminate gaps and irregularities where moisture intrusion may lead to corrosion.
As such, Stopaq requires very minimal surface preparation (no primers) which drastically reduces labor costs and application time. It also allows for easy maintenance that requires little time to repair damage without needing abrasive blasting or complicated scaffolding. The system can be painted to match aesthetic requirements, making it an environmentally friendly and costeffective option for long-term tank protection.
INTEGRATED SYSTEMS: A COMPREHENSIVE APPROACH TO ASSET PROTECTION
The operators of storage tanks can adopt an integrated protection approach, which includes internal linings, external coatings, thermal insulation, cathodic protection, and wrapping systems. This multi-layered approach to corrosion protection from different angles ensures longevity in service and operational reliability.
In the most demanding applications, such as coastal or industrial environments, these integrated solutions have been shown, in practice, to deliver up to 25 years of maintenance-free service. This minimises lifecycle costs, improves safety, and ensures storage tanks can continue to meet the changing needs of industry today and into the future.
MANAGING SAF PRODUCTION
How a new technology is indispensable for managing SAF production for airlines
The aviation industry faces a pressing need to decarbonise, with Sustainable Aviation Fuel (SAF) emerging as a key solution. However, SAF production presents significant challenges, including optimising complex catalytic processes and ensuring consistent product quality. This is where realtime, monitoring with a technology such as the Daily Thermetrics CatTracker becomes indispensable, according to the company.
THE CHALLENGE OF SAF PRODUCTION
SAF production typically involves upgrading existing refinery infrastructure to process renewable feedstocks like used cooking oil, agricultural residues, and municipal solid waste. This often entails integrating a variety of new catalytic processes, such as hydroprocessing and isomerisation, into existing refinery operations.
These processes are intricate, with numerous variables impacting catalyst performance and product quality. These variables include:
Feedstock variability: Renewable feedstocks can exhibit significant variations in composition, impacting catalyst activity and selectivity.
Catalyst deactivation: Catalysts gradually lose activity owing to coking, poisoning, and sintering, necessitating adjustments to operating conditions.
Product specifications: Stringent quality standards for SAF, including carbon content, energy density, and freezing point, must be consistently met.
THE ROLE OF THE DAILY THERMETRICS CATTRACKER
The Daily Thermetrics CatTracker provides real-time, in-situ monitoring of catalyst performance within refinery reactors. It employs embedded temperature sensors to measure precise temperature profiles along the catalyst bed.
HOW THIS TECHNOLOGY IS CRITICAL FOR SAF PRODUCTION:
Early detection of catalyst deactivation: By continuously monitoring temperature profiles, CatTracker Technology can detect subtle changes indicating catalyst deactivation, such as: Hotspots: Localised temperature increases owing to decreased catalyst activity, potentially leading to reactor damage or runaway reactions.
Temperature gradients: Changes in the temperature profile along the catalyst bed, signaling variations in catalyst activity or flow distribution.
EARLY DETECTION HELPS FLEXIBILITY
Early detection allows for proactive adjustments to operating conditions, such as increasing feed flow rates or implementing regeneration procedures, maximising catalyst lifetime and minimising downtime.
Above: CatTracker temperature profiling (radial)
OPTIMISATION OF OPERATING CONDITIONS:
CatTracker data provides valuable insights into the impact of operating variables on catalyst performance, enabling real-time optimisation of:
Feedstock quality: By monitoring catalyst response to variations in feedstock composition, refineries can adjust processing parameters to maintain optimal performance.
Reactor temperature: Precise temperature control is crucial for maximising product yield and minimising side reactions. CatTracker data allows for fine-tuning temperature profiles to match desired product specifications.
Space velocity: CatTracker helps determine the optimal flow rate of feedstock through the reactor, ensuring efficient use of catalyst capacity.
Enhanced product quality control: By correlating CatTracker data with product quality analysis, refineries can establish robust relationships between catalyst performance and product specifications.
THIS ENABLES:
Predictive maintenance: By anticipating potential issues with product quality, refineries can take corrective actions before they impact downstream operations.
Reduced off-spec production: Minimising the production of offspecification SAF reduces waste, improves operational efficiency, and lowers production costs.
IMPROVED PROCESS UNDERSTANDING:
CatTracker data provides a wealth of information about the complex interactions within the reactor, enhancing process understanding and enabling:
Catalyst development: By analysing CatTracker data from various catalyst formulations, researchers can gain insights into catalyst behavior and develop more efficient and durable materials.
Process scale-up: CatTracker data collected during pilot plant studies can be used to optimise and de-risk the scale-up of SAF production processes to the required commercial scale.
CatTracker: assembly
CatTracker routing and installation
BENEFITS OF THE TECHNOLOGY
Increased profitability: By optimising catalyst performance, maximising product yield, and minimising downtime, CatTracker contributes to significant cost savings and improved profitability. Reduced environmental impact: By optimising processes and minimising waste, CatTracker helps reduce the environmental footprint of SAF production.
Enhanced safety: By detecting potential hotspots and preventing runaway reactions, CatTracker improves process safety and minimises the risk of accidents.
Improved sustainability: By enabling the production of highquality SAF from renewable feedstocks, CatTracker plays a crucial role in the transition to a more sustainable aviation industry.
CONCLUSION
In the drive towards a decarbonised aviation sector, SAF production is a critical component. However, the successful and sustainable production of SAF requires advanced
technologies that enable real-time monitoring and optimisation of complex catalytic processes.
Daily Thermetrics CatTracker offers a powerful solution by providing continuous, insitu monitoring of catalyst performance. By leveraging the insights gained from CatTracker data, refineries can:
• Optimise catalyst performance
• Improve product quality
• Reduce operational costs
• Enhance process safety
• Minimise environmental impact
Ultimately, in addition to being a temperature measurement instrument, the tool is an enabler of a more sustainable and efficient future for aviation.
By embracing this technology, the industry can accelerate the transition to a cleaner, greener, and more sustainable future for air travel. For
THE NEW NORMAL
John Calder technical director at Durapump tells us where and how smart pumps are being used, and why he expects them to become mainstream in 2025
As we move into the new year a pump expert has predicted that 2025 will be the year that smart monitoring and digitalisation in IoT pump monitoring will come to the fore across the sector.
Smart pumps have seen a significant increase in demand, with forecasts predicting growth at a CAGR of 8.5% between 2023 and 2028 and this growing adoption could help the global pumps market reach £72.7bn by 2029.
In this article, John Calder, technical director at Dura Pump, explains why he thinks 2025 will be a big year for smart pumps.
The technology is currently being used for three key functions within industrial settings: delivering boosted water, improving heating and cooling efficiency, and reducing blockages in wastewater systems.
Using smart pumps to deliver boosted water is particularly important for increasing the efficiency of energy consumption. At Dura Pump this application is most specifically seen in relation to large sites like hospitals or healthcare settings. In this case, smart pumps are equipped with permanent magnet motors (PMMs) and inverters to monitor pumping operation and conditions.
This could highlight excessive or low demand from a site, indicating that a valve is shut or that there’s a break in the pipework, for example. The pumps can also monitor the temperature of the motor, highlighting any potential wear on bearings or a winding failure, as well as monitoring the feed temperature from the water tank to alert of any risk of legionella.
We’re also seeing smart pumps being utilised in the distribution of heating water around sites through a district heating system. Whereas historically these systems would run at a constant speed regardless of
demand from the system, smart pumps mean we can now monitor the return temperature of water and modulate the pumps accordingly. The third common application of smart pumping solutions is the monitoring of wastewater systems around blockages from a build up of fat or foreign objects in the wastewater system. This can be very expensive, both in terms of downtime as well as the extra expense of paying trucks to take wastewater offsite.
Smart pumps can monitor pumping conditions and the power being used by pumps and, if a blockage is detected, the pump can reverse and throw the blockage or debris back out of the system.
At Durapump we work with a number of prisons on this application of smart pumps. As well as the build up of fats from kitchens, for example, these facilities are all-to-familiar with the presence of foreign objects in their wastewater systems.
All of these smart pump systems can also monitor conditions to highlight any signs of wear and tear, and alert when a pump needs to be serviced ahead of any potential issues. With remote monitoring, key individuals can view the status of pumps and be alerted of any issues by text or email.
WHY IS 2025 THE YEAR OF SMART PUMPS?
As the Internet of Things (IoT) becomes all embracing, the cost of sensors, conductivity and supporting networks to carry information is improving. This will reduce the requirements for unnecessary maintenance because we will know exactly what the pump and system needs.
As more data is gathered, we can continue to increase the accuracy and range of predictions. Vibration signatures, for example, can tell us the condition of bearings or whether the pump is cavitating.
SENSORS ARE MORE AFFORDABLE FOR BUSINESSES
Sensors have become much more affordable for businesses and organisations, particularly when compared with the increase in the price of energy. Although the cost of monitoring remains relatively expensive, the potential ROI from major reductions to energy consumption will make the decision to invest much easier, this will also drive demand.
Reliability is key in any industrial setting and downtime is prohibitively expensive. With the increase in applications of AI and machine learning, smart pumps will be able to optimise systems even further and when this is expanded across all components within a system, the savings become even more significant.
Calder has been working with businesses to help minimise downtime and interruptions to pump systems for almost 20 years and expects to see this growth accelerate in the year ahead.
John Calder, Durapump
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IChemE is a market leader in professional training for the chemical, process and related industries.
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Process safety
█ Hazard identification and risk analysis techniques (including HAZOP and LOPA)
█ Process safety management
█ Understanding different hazards (eg hydrogen)
█ Human factors in the chemical and process industries
Contract and project management
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█ Engineering project management
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Process and plant operations
█ Chemical engineering core concepts
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█ Plant and production management
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█ Introduction to sustainable process engineering
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SMART SAFETY
How
5G and AI
will help improve safety and performance in hazardous environments
As in all other industries, it is becoming increasingly important to ensure safety, productivity and operational efficiency in chemical processing, oil and gas refining and pharmaceuticals. The integration of advanced digital technologies, especially specialised mobile devices, is key to improving both worker safety and operational performance in hazardous environments.
OPTIMISING SYSTEM CONNECTIVITY FOR SMARTER OPERATIONS
The digital transformation of industrial operations depends on the seamless integration of machines, sensors, and systems. In hazardous environments, this integration is crucial for real-time monitoring, predictive maintenance, and process optimisation. Certified mobile devices, such as the IS940.1 tablet and IS540.1 smartphone from i.safe Mobile, enable workers to access real-time data through 4G/5G networks and Wi-Fi 6, facilitating continuous data exchange across plants. This integration enhances transparency and enables better decision-making in the field.
AI AND DIGITAL TWINS: ENHANCING EFFICIENCY
Artificial intelligence (AI) is vital for predictive maintenance and process optimisation. AI algorithms can predict issues before they disrupt operations,
while suitable mobile devices support data-driven decisions with real-time information. Digital twins (virtual models of physical assets) allow for enhanced remote monitoring and analysis of machine performance. Together, AI and digital twins improve decision-making, reduce waste, and minimise energy consumption.
IMPROVING COMMUNICATION AND MINIMISING RISK
In hazardous industry environments, reliable communication is crucial, as even small disruptions can lead to serious consequences. Mobile devices certified for such areas ensure consistent communication between field workers, supervisors, and control rooms. Features like real-time video streaming, remote support, and augmented reality (AR) are invaluable for troubleshooting and inspections. These tools improve safety by enabling remote repairs and inspections in high-risk zones, reducing the need for worker exposure to danger and ensuring resources are allocated efficiently.
THE IMPACT OF 5G ON INDUSTRIAL SAFETY AND EFFICIENCY
5G technology is transforming industrial communication. With ultra-low latency, high stability, and secure data transmission, 5G enables faster decision-making and reliable remote monitoring. Devices
Workers using i.safe movbile devices
like the 10.1-inch IS940.1 tablet and the 6-inch IS540.1 smartphone, both 5G-enabled and ATEX/IECEx approved, allow operators to manage complex processes in explosive areas. Ground-breaking developments such as the forthcoming i.safe Mobile hazardous area docking solution will further increase efficiency and safety by enabling continuous charging, data transfer and peripheral device integration. The Windows version of the i.safe Mobile tablet will also be available over the course of the year, making even more applications and an extended target group possible.
A FUTURE POWERED BY CONNECTIVITY, AI, AND 5G
The future of industrial operations, particularly in hazardous environments, will be shaped by mobile technology, AI, and 5G networks. These innovations will provide workers with real-time communication tools, AI-driven insights, and remote assistance, enhancing safety and operational efficiency. As technology advances, industries can look forward to a safer, more connected, and more efficient future.
Author: Jan Rieks Zonderman, product manager automation, i.safe Mobile
Understanding the combustible properties of your facility’s dust is crucial to preventing devastating dust explosions. If you have questions about your dust, need testing or analysis of previous results, we’re here to help!
FIKE DUST TESTING INCLUDES:
• Explosibility Screening
• Kst & Pmax
• Minimum Explosible Concentration
• Limiting Oxygen Concentration
• Minimum Ignition Energy
• Minimum Ignition Temperature
• Minimum Auto Ignition Temperature
AGAINST THE GRAIN
How to deal with potential combustible dust when grinding and drying grain
Processes that involve grinding, drying, conveying and storing grain pose some of the biggest risks for combustible dust explosions.
But what makes combustible dust hazards particularly concerning in this industry? It is worth looking at the variety of processes at play:
Grinding: This process breaks grain kernels down into smaller particles, significantly increasing the surface area of the dust and making it more combustible.
Drying: Grain drying often involves using heated air, which can further dry out dust, making it more susceptible to ignition.
Conveying: Equipment such as elevators and drag conveyors move grain around facilities, disturbing combustible debris that creates dust concentrations within enclosures and at transfer points.
Storing: Grain storage silos and bins can accumulate dust over time, and dust becomes suspended in high concentrations while workers fill silos.
HOW TECHNOLOGY HAS MADE GRAIN MILLING SAFER
While we’re not so far advanced that we can ignore combustible dust altogether, innovative technology has made grain milling much safer than it was a century ago. With the right equipment and engineering controls in place, facilities can reduce the risk of devastating explosions.
VENTING PANELS AND FLAMELESS VENTS
Explosion venting panels (or rupture panels) are designed to relieve pressure and gases from an explosion within a contained area, such as a dust collector or silo. They work by opening rapidly during an explosion,
allowing the release of pressure in a controlled manner. Flameless vents incorporate the same explosion vent panels along with a system of layered mesh that quenches flames following an explosion, allowing indoor vessels to vent without causing injury or damage to personnel or property.
PASSIVE EXPLOSION ISOLATION SYSTEM
A passive explosion isolation equipment, such as Boss Products’, Vigifl ap, is designed to isolate explosions within equipment enclosures, preventing the hazardous spread of fi re and reducing the chance of a secondary explosion. Passive systems are generally more straightforward in design and operation compared with active systems, they also have a lower one-time cost and are easier to maintain, according to the company. In fact, facility personnel can do inspections themselves.
The Boss Products Raptor Spark Detection and Extinguishing System is a safety device designed to detect and extinguish sparks
SPARK DETECTION SYSTEMS AND MONITORING SOLUTIONS
Spark detection systems detect live embers and sparks in airstreams to prevent ignition sources from reaching equipment enclosures where devastating explosions can happen. On the other hand, monitoring systems are particularly useful in grain facilities for equipment like bucket elevators and conveyors. Unlike spark detectors, which work by identifying live embers, monitoring systems detect potential ignition sources such as hot bearings, belt misalignment and choked chutes. Boss Products UK offers safety solutions for combustible dust collection and control to manage fire and explosion risk in grain facilities.
The Vigiflap is a passive explosion isolation unit
DEMYSTIFYING DUST
How dust testing can lead to process improvements and reduce the risk of an explosion
Avariety of dusts possess explosible properties, and therefore when certain conditions are met, such as the dust being dispersed and enclosed and an ignition source being introduced, combustion is likely to occur. Some combustible dusts include flour, sugar, milk powder, wood, plastics and metal, and countless other variables that must also be considered such as particle sizes and mixtures.
That’s why knowing the combustible properties of the dust handled in your facility is often the first step towards avoiding a devastating dust explosion. Let’s look at three specific types of ‘sensitivity’ dust tests, and how documenting certain explosive properties can be used to leverage process adjustments and facilitate explosion prevention efforts.
Minimum ignition temperature of a layer | MIT (layer) -This measures the lowest surface temperature required to ignite a layer of dust.
How data may be used: Both monitor and mitigate the hot surfaces within a process to ensure they remain under the dust layer’s MIT.
Applicable standards: ‘ASTM E2021, Standard Test Method for Hot Surface Ignition Temperature of Dust Layers’ & ‘EN 50281-2-1.’
How data is documented: Aluminum plate is heated to various temperatures in which smoke or combustion is observed from the dust sample; the lowest temperature resulting in ignition is the MIT (Layer).
Temperatures of dust layers: Low = <300°C | Med = 300°C - 450 °C | High = >450 °C.
The lower the MIT, the more susceptible it is to combustion from a hot surface.
Minimum ignition temperature of a cloud | MIT (cloud) - Indicates the
Clean Energy Safety Solutions
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Supporting a Safer Journey to Net Zero
Dräger, with a legacy spanning over 100 years, is your trusted safety partner in this journey. We deliver comprehensive safety solutions tailored for the evolving clean tech landscape. From gas detection and respiratory protection to service and rental, we’re dedicated to protecting your team and assets in the face of new challenges across various sectors — be it hydrogen, carbon capture, battery production, offshore wind, waste-to-energy, or nuclear. We are not just a supplier; we are a partner in your journey towards a safe and sustainable future.
lowest thermal ignition required for a dust cloud to self-ignite.
How data may be used: Ensure conveyed air or volumes within ovens, for example, stay below the dust cloud’s MIT.
Applicable standards: ‘ASTM E1491, Standard Test Method for Minimum Auto Ignition Temperature of Dust Clouds’ & ‘EN 80079-20-2 and & ‘EN13822’.
How data is documented: Exposes a dust cloud to varying temperatures until self-ignition is and is not observed. The MIT (cloud) is the lowest ‘boundary’ temperature over a range of dust concentrations.
Temperatures of dust clouds: Low = <400°C | Med = 400°C - 600 °C | High = >600 °C.
The lower the MIT (cloud), the more susceptible a dust cloud is to combustion from sources such as hot conveyed air.
Minimum Ignition Energy | MIE
- Determines the lowest amount of electrical discharge required to ignite a dust cloud.
How data may be used: Bonding and grounding may be used in areas identified to have risk of electrical discharge and help prevent or mitigate high energy buildup within the process.
Applicable standards: ‘ASTM E2019, Standard Test Method for Minimum Ignition Energy of a Dust Cloud in Air’ & ‘EN 80079-20-2” & “EN 13822’.
How data is documented: A dust sample is pneumatically dispersed into a cylinder while a spark is generated across two electrodes. The MIE is the average of the lowest energy at which ignition of the dust cloud is observed and the highest energy at which ignition is not observed.
Ignition energies: Very low = <10 mJ
| Low = 10-30 mJ | Med = 30-100 mJ | High = >100 mJ.
The lower the MIE, the more susceptible the dust cloud is to ignition from electrostatic discharge.
Once these explosibility values of the unique dust found within your process are documented, a risk assessment specialist will then be able to know where potential combustible dust hazards may or may not exist in the facility. Therefore, certain areas of the process where the dust is determined to be non-combustible, or with a very low severity or likelihood of igniting, may be deprioritised in favor of areas that could result in harm to workers or extensive damage to the process if combustion were to occur.
Furthermore, the risk assessment specialist will use these explosibility characteristics to suggest areas of the process that may require temperature monitoring to ensure a surface doesn’t reach a dust layer’s MIT, methods of minimising dust concentrations or
the formations of dust clouds where elevated air is conveyed, and more. Finally, not only do both NFPA and ATEX require the documentation of the process’s dust explosibility characteristics, but this information is also critical during the design of explosion protection equipment, including explosion venting, suppression and isolation systems. Whether you need to identify the explosibility of the dust handled in your facility or have already completed dust testing but are unsure what to do next, it’s important to work with a trusted dust testing provider to both perform the dust testing and analyse the results with you to ensure reliable prevention and protection from explosions.
Hartman Tube ingnition test
Explosion Venting
Explosion venting devices limit the overpressure and mitigate damage to process equipment by controlled venting of the excess pressure with or without flame to a safe area. ATEX explosion venting systems offer an economical, cost-effective means for explosion protection. We have the latest and best in explosion venting technology, over 50 years of practical design knowledge and up to date computer modelling.
Explosion Suppression
Explosion Suppression Systems are fast fire extinguishing systems that detect the explosion pressure in a protected plant and then mitigates the flame/pressure damage to an acceptable level. For the very best in explosion suppression solutions, view our full range of ATEX solutions.
Explosion Isolation
Most processes involve interconnection with associated vessels. To prevent propagation to other vessels, it is essential to apply appropriate explosion isolation devices to prevent flame, spark and/or pressure from transmitting to the other vessels. For the very best in explosion isolation solutions, view our full range.
CO ACOM Systems
The Atex CO detection system uses advanced carbon monoxide (CO) sensors to detect early stages of powder combustion before a fire or explosion can be ignited.
Email: info@explosionhazards.com
Explosion Hazards Limited
Experts in explosion safety for over 50 years
THE VALUE OF STRUCTURED DATA
Strengthening work and plant safety with data analysis
Digital technologies such as the Industrial Internet of Things (IIoT) provide plant operators with enormous amounts of raw data on technical operating processes, machine statuses and working environments. To utilise the potential of this data, it is important to translate the raw data into helpful insights using data analytics. The data structured according to specific criteria can be of great value to plant operators by increasing the efficiency of processes, extending the service life of machines and equipment, and improving occupational safety for all employees.
Especially in the process industry, the information obtained through data analysis is of great benefit. It reveals patterns and correlations,
provides information on cyclical fluctuations and trends, and identifies anomalies and weak points. In a corporate culture based on data analysis, more informed decisions can be made in a shorter period of time. A good example of the use of data analysis is predictive maintenance. For example, by analysing gas sensor data, IIoT systems can predict potential equipment failures before they occur. This reduces downtime and maintenance costs. Predictive maintenance also improves occupational safety by minimising the risk of unexpected system failures, that could put employees at risk.
LIVE DATA FOR AREA MONITORING
Another application scenario that is
becoming increasingly important for occupational and plant safety in the process industry is live monitoring, i.e. automated area monitoring based on live data. This involves linking gas measuring devices for data acquisition with a powerful, cloud-based software system that can store and process large volumes of data and make it available at once.
Live monitoring particularly shows its strengths in the field of extended area monitoring, when a large amount of measurement data is fed live into the system – this is then processed in a targeted manner. In this way, live monitoring maintains safety standards during plant operations and identifies safety gaps. The immediate detection of hazardous situations allows alarms to be triggered quickly, warnings to be
The Draeger ConHub can transmit data from up to 20 personal gas detection devices
sent and protective rescue measures to be initiated.
To achieve good results, a live monitoring system must meet several requirements: It should be suitable for different use cases, be easy to use, mobile, ensure both the data protection of users, i.e. the employees and contractors in the operating facilities, and the security of the company data obtained.
CLOUD-BASED SOLUTION FOR DATA STORAGE AND PROCESSING
Dräger’s live monitoring solution is a good example of how this works. Its centerpiece is Gas Detection Connect (hereinafter GDC). The Microsoft Azure-based cloud software can be networked with mobile gas detectors and a stationary area monitoring device; the data is transmitted live. The advantage of the cloud-based system is that all relevant information is available right where it is needed. The devices can also be managed efficiently from any location using remote access.
Live monitoring with GDC is suitable for various applications. In conjunction with a smartphone app, it can protect employees or contractors who work alone (lone workers), for example during inspections outside business premises. In these cases, the app on the smartphone connects via Bluetooth to a portable, wearable, gas detector. This transmits the device data such as gas or a panic alarm which then becomes available in the cloud. In addition to alarms and gas measurement data, the employee’s location is also transmitted. Data privacy issues must therefore be clarified before use.
LARGE AMOUNTS OF DATA FACILITATE HAZARD ANALYSIS
When it comes to obtaining data from industrial areas in which several employees or contractors are working at the same time, for example for maintenance and repair work, live monitoring can be carried out with the explosion-proof Dräger ConHub. The portable gateway can transmit data from up to 20 personal gas detection devices located within its
range to the cloud. To do this, the gas detectors connect to the ConHub via Bluetooth. The position detection with built-in GPS makes it possible to assign the individual devices to the respective position of the ConHub – without transmitting a person’s specific location.
An advantage is that no SIM card mobile device (direct to cloud) is required here. The background to this is that these devices are dependent on constant Broadcom connectivity. Shadow effects in dense industrial areas can lead to network problems. All the gas detection devices that can connect to the ConHub at the same time can provide large amounts of data, providing a deeper insight into potential danger zones. On the one hand, the data makes it easier to take suitable measures in good time, for example in the event of an accident. On the other, the analysis of the collected data allows conclusions to be drawn about the hazard potential of monitored areas and can therefore contribute to hazard prevention.
The complexity of operating facilities in the process industry is constantly growing. At the same time, the demands on both plant performance and compliance are also increasing. Overcoming these challenges will only be possible through the consistent integration of technologies such as IIoT and cloud computing, which can deliver and process large volumes of data within a facility.
The aim must be to further develop existing solutions in this field based on specific customer needs and requirements and to always use the most meaningful data to ensure that the process industry remains safe, efficient and future-proof. Overall, the security of the data should have the highest priority. To ensure this, Dräger is taking various measures.
GDC live monitoring is suitable for various applications
FROM PREDICTIVE TO PRESCRIPTIVE
Dijam Panigrahi COO of GridRaster explores how agentic AI is reshaping manufacturing operations
The progression of intelligent automation in manufacturing and supply chain management has been pretty groundbreaking. From the early days of the Industrial Revolution to today’s era of smart factories and agentic AI, the journey has been marked by continuous innovation and adaptation. The recent integration of information technology with automation led to the development of programmable logic controllers
(PLCs) and computer numerical control (CNC) machines, allowing for more complex and precise automation processes. The introduction of the internet further transformed logistics, enabling real-time tracking and data analytics to optimise supply chains.
HOW INDUSTRY 4.0 IS EVOLVING
Today, we find ourselves in the midst of Industry 4.0, characterised by the fusion of digital, physical, and
Industry 4.0 is characterised by the fusion of digital, physical and biological worlds
biological worlds through advanced technologies such as the Internet of Things (IoT), artificial intelligence (AI), and big data analytics. This new era has given rise to smart factories, where machines can communicate with each other and make autonomous decisions to optimise production processes.
INTRODUCING AGENTIC AI IN MANUFACTURING
The latest frontier in this evolution is the emergence of agentic AI, a progressive technology that combines autonomous decision-making with real-time adaptability. Unlike traditional automation, agentic AI enhances efficiency, reduces costs, and fosters sustainable practices, making it indispensable for smart factories.
Agentic AI is reshaping manufacturing processes in several key areas. One of the most significant is predictive maintenance. Traditional maintenance models are reactive, addressing failures after they occur. In contrast, agentic AI enables predictive maintenance, where systems monitor machinery in real-time, identifying signs of wear or potential failure before they disrupt production. This not only saves costs but also enhances efficiency by allowing manufacturers to schedule repairs at optimal times, avoiding unexpected disruptions.
For inventory management, agentic AI systems use real-time data and demand forecasts to optimise stock levels, ensuring the availability of raw materials while avoiding overstocking. Autonomy here reduces carrying costs and improves supply chain efficiency, allowing manufacturers to maintain lean inventories while meeting production schedules seamlessly.
In robotic assembly lines, agentic AI enables dynamic task allocation and real-time adaptability. Unlike traditional robots that follow preprogrammed instructions, AI-powered robots learn from their environment and adjust to changing tasks on the fly. This significantly reduces errors, optimises resource usage, and enables scalability in production, making them a cornerstone of smart factory operations.
It’s important to understand that the implementation of intelligent automation and agentic AI in manufacturing is not about replacing human capital. Instead, it’s about reallocating human resources to other critical areas of manufacturing planning, business operations, analysis, operations, and reporting functions.
Through automating repetitive and time-consuming tasks, agentic AI
frees up human resources for strategic decision-making activities, which allows manufacturers to leverage their workforce’s creativity, problem-solving skills, and adaptability in areas where human input is most valuable.
The adoption of intelligent automation and agentic AI is also changing the paradigm of how manufacturers view software solutions. Instead of merely leveraging software as a service, the industry is evolving toward service as software functions within the business through agentic automated decisioning opportunities. This shift allows for more integrated, customised, and responsive solutions that can adapt to the unique needs of each manufacturing operation.
THE USE OF DIGITAL TWINS
A key component in the implementation of automated decisioning across these industries is the use of digital twins. A digital twin is a virtual representation of a physical object or system, updated in real-time using data from sensors in the physical world. In manufacturing, digital twins of production lines or
entire factories allow for real-time monitoring, predictive maintenance, and optimisation of operations.
For example, in aerospace manufacturing, a digital twin of an aircraft engine can be used to simulate different operating conditions, predict wear and tear, and optimise maintenance schedules. In automotive production, a digital twin of the assembly line can help identify bottlenecks, optimise workflows, and even test new production configurations virtually before implementing them in the physical world.
The integration of digital twins with agentic AI takes this concept even further. AI algorithms can analyse the vast amounts of data generated by digital twins to make autonomous decisions and optimisations. For instance, an AI system could use data from a digital twin of a manufacturing plant to automatically adjust production parameters in realtime, optimising for factors such as energy efficiency, output quality, and equipment lifespan.
As we look to the future, the potential of intelligent automation and agentic AI in manufacturing seems boundless. These technologies are not just improving efficiency and reducing costs; they’re enabling new levels of customisation, sustainability, and innovation. By 2025, it’s predicted that AI-powered automation could save manufacturers up to 25% of their operational costs.
The evolution of intelligent automation, culminating in the current era of agentic AI, represents a true shift in manufacturing and supply chain management. By embracing these technologies, manufacturers can improve their operational efficiency and decisionmaking processes while also freeing up their human workforce to focus on more strategic, creative, and value-adding activities.
Dijam Panigrahi is co-founder and COO of GridRaster, a provider of cloud-based platforms that power high-quality digital twin experiences on mobile devices for enterprises.
APEC
Specializing in the design and manufacturing of ingredient automation equipment and controls for liquid coating and handling, continuous feeding, mixing and blending, weighing, batching, material handling and automation controls.
T +1 (616) 374-1000
E terrys@apecusa.com
W www.apecusa.com
LabFacility
The UK’s leading ISO 9001-accredited manufacturer and supplier for the complete temperature chain. From Temperature Sensors, Thermocouple Connectors and Cabling to supporting instrumentation and components, we are the GO-TO peopley.
T +44 (0) 1243 871280
E Sales@labfacility.com
W www.labfacility.com
Boehmer
Böhmer has focused on one product - the ball valve. The portfolio is nevertheless more than impressive: The application-optimized valves in the nominal sizes from DN 3 (1/8”) to DN 1400 (56”) are available in around 100,000 different designs..
T +49 2324 / 7001-925
E oertgen@boehmer.de
W www.boehmer.de
HILLIARD
Hilliard offers a diversified product line for industrial applications in a wide variety of industries. Hilliard products are designed, manufactured and sold according to our customers’ applications.
T +1 607 733 7121
E rdoud@hilliardcorp.com
W www.hilliardcorp.com
Rotork
A market-leading global provider of mission-critical flow control and instrumentation solutions for oil and gas, water and wastewater, power, chemical, process and industrial applications.
T +44 (0) 1225 733200
E mail@rotork.com
W www.rotork.com
Greenwich University
Wolfson Centre
Providing cost-effective solutions to industrial problems: Consultancy services and training for industries that handle powder or granular materials as part of their processes.
T +44 20 8331 8646
E wolfson-enquiries@gre.ac.uk
W www.bulksolids.com
(0)207 253 2545
CLEAR VISION
Infineon has expanded the capabilities of its AI Deepcraft studio to include computer vision
AI has many different applications, and one of them is sight. This is a potential gamechanger for machine learning developers as it means a direct hit of information, less coding and a more ‘human’ means of interacting with the environment.
With this in mind, business solutions company Infineon Technologies has released support for computer vision in its Deepcraft Studio - a platform that enables end-to-end development of Edge AI applications for embedded devices. This addition expands on the existing support for audio, radar and other time-series data.
The addition is being supported by Ultralytics, an AI leader and creator of YOLOv5, YOLOv8, and YOLO11 object detection models. The product powers ‘cutting-edge computer vision across industries with 72M+ Pip downloads, 100K+ GitHub stars, and 5,000+ research citations,’ according to the company.
With the addition, the platform can now develop low-power, low-memory Edge AI models for vision. Use cases for this updated AI implementation will include factories wanting to conduct real-time visual inspection of parts, for example, or shut down machinery in the presence of a human; or Smart Home appliances looking to monitor objects, humans, or pets; for example.
Alexander Samuelsson, product manager Deepcraft Studio said: “These updates will optimise each step in AI model development for vision-based use cases, starting with data collection and preprocessing and all the way through model deployment,” he continued, “this means we are offering developers end-toend support for vision. When coupled with Infineon’s PSOC Edge high performance machine learning MCUs, our customers will be well-equipped to add a range of high end Edge AI features to their products.”
Infineon will showcase this capability in a computer vision demo at Embedded World 2025 in Nuremberg this March. The detection will be powered by Ultralytics YOLO models, enabling developers to train custom computer vision solutions. Leveraging Ultralytics Yolo models will significantly reduce training time while maintaining high accuracy. These additions to the Deepcraft Studio paired with the platform’s unique graph-based UX interface enable iterations on models during the development cycle. Developers can run their model in real-time using their
own computer and camera, making sure it works as intended before deploying onto hardware. This speeds up development, as improvements can be made to the model before it is deployed.
AVAILABILITY
Infineon will launch a new version of the studio with support for vision in April.
Infinion’s Deepcraft Studio now supports vision
HANNOVER MESSE: ONE OF EUROPE’S LARGEST TRADE SHOWS
The show, to take place in Hannover between 31 March and 4 April 2025, will see companies from the mechanical engineering, electrical engineering and digital industries come together to present solutions for a high-performance and sustainable industry. More than 4,000 companies will be in attendance to demonstrate how climate neutrality can be achieved through electrification, digitisation and automation.
The show will focus on all things digital with the smart manufacturing section showing and discussing sensors, embedded systems, logistics automation, material handling and assembly, and robotics.
A digital ecosystem section will look
at additive manufacturing, digital platforms, edge computing and the seemingly ubiquitous AI.
More than 300 startup companies are expected to attend, bringing together original minds and pioneers. The start-up area will include a presentation booth, offering opportunities to participate in challenges and pitches.
More than 3,500 exhibitors have already signed up to the show, with 7,800 products currently listed. 161 research institutions will also be in attendance.
This year, Hannover Messe’s partner country is Canada. The country has expertise in fields like AI, quantum, electric vehicles, advanced materials and more - this promises to be a fruitful collaboration.
Running as part of the CHEMUK 2025 Group of Events
2 Packed Days
Hundreds of Exhibitors
Panel Sessions
Plant & Process Intensification
Control & Instrumentation
CHEMICAL 4.0
Automation / Digitisation
Plant Management
Flow & Thermal Solutions
Thousands of Specialist Products...
CHEMUK: A ‘MUST ATTEND’ FOR CHEMICAL ENGINEERS
CHEMUK 2025, the largest UK B2B trade show supporting the chemicals, process engineering and formulated product industries, is to take place on the 21st and 22nd May 2025 in hall 5 at the NEC in Birmingham. The show is aimed at chemical engineers and is free to attend.
The show’s website states the following: “Every year we present
exciting features and projects that demonstrate real-world innovative products, solutions, and materials derived from ground-breaking chemistries while reflecting collaborative industry research and partnership.”
As with most B2B shows, a mainstay is the exhibitors and CHEMUK expects to host more than 500 this year. There will also be more
As with most B2B shows, a key draw is the exhibitors, and CHEMUK expects to host more than 500 this year
than 100 expert speaker sessions, split between the following five focused zones: the Chemicals Supply Show Zone, the Chemicals Management Show Zone the Process & Chemical Engineering Show Zone and the Chemical Laboratory Show Zone.
In addition, there will be a new area this year: the Formulated Product Manufacturer Show.
The CHEMUK 2025 speaker programme features more than 150 contributing speakers presenting more than 50 hours of keynotes, feature sessions, and panel discussions running across the show’s five auditoriums. A full speaker programme will be announced on the 19th May and registrants will be updated via their e-newsletter updates. Session themes will include chemical and product labelling; chemical business management; chemical sector markets; chemicals sourcing and procurement; chemistry innovations; digital transformation; sustainable chemistry and more.
The show is supported by a number of leading innovation support organisations including the Henry Royce Institute, RSC Changermakers, Innovate UK, Aston University, Materials Innovation Factory, Centre for Process Innovation, and the Biorenewables Development Centre. The networks will help attendees develop their products and solutions. Special features at the show include Waste2Race: Engineers and students at WMG at The University of Warwick are working on a hydrogen-powered car fuelled by sewage in a project entitled Waste2Race. The car is ‘on track to make history,’ according to the webiste. The hydrogen used is a byproduct of water treatment technology, from Wastewater Fuels, being trialled at Severn Trent Water, and with it the team at the University are hoping to break records for hydrogen fuelled cars.
Balance the chemical equation
Chemical processes need finesse as well as force. With gearless direct drive systems from Hägglunds, you gain stepless control over torque and speed in your reactors, mixers, agitators and more. Protected by our EX-proof motors, built-in torque limitation and cutting-edge condition monitoring, you can achieve conditions that improve your product – and your competitiveness. We drive what drives you.
Hägglunds is a brand of Rexroth. www.hagglunds.com
