Process Technology Jun/Jul 2025

welcome COVER FOCUS

Bronkhorst believes progress comes from long-term commitment, trust, and a deep understanding of its customers’ challenges. Founded in 1981 in the Netherlands, the company has grown from a small, determined team into a global leader in low-flow measurement and control equipment and services. Yet the approach remains the same — staying practical, making deliberate choices, and always putting relationships first. Today, Bronkhorst’s instruments and expertise are trusted in over 100 countries, helping customers and partners achieve accuracy, reliability, and sustainable results.

Bronkhorst doesn’t just supply instruments; it provides solutions. That means taking the time to truly understand customers, their processes, and the challenges they face. The right answer requires knowledge, but also the ability to listen, think ahead, and act decisively.

At Bronkhorst, mastery is at the core of the business. As a low-flow specialist, Bronkhorst is dedicated to delivering expertise and precision in every solution. Pioneering drives the company forward, embracing innovation, to create real value for customers. Collaboration is essential for Bronkhorst, both within the company and in how it works with customers and partners to develop the best possible solutions. Bronkhorst seeks to ensure that its decisions today support long-term sustainable success, with a focus on efficiency, responsible resource use, and lasting relationships.

AMS is proud to represent Bronkhorst in Australia and New Zealand.

Australia’s critical utilities are becoming increasingly digitalised, aiming to improve efficiency, reliability and environmental sustainability. But this increasing digitalisation and connectivity also introduces significant cybersecurity risk, and with the introduction of the SOCI Act proactive investment in cybersecurity is no longer optional. Now, as if this challenge was not enough, a new cybersecurity threat looms over the horizon in the form of quantum computing, which is expected to have the ability to break current cryptographic standards, particularly public-key encryption methods commonly used in SCADA systems. While the threat may still be several years away, it is not theoretical, and for Australia’s water, wastewater, and energy utilities, quantum computing represents a new paradigm of risk that must be prepared for today.

Meanwhile, the digitalisation of control networks is not the only way in which the process industries are experiencing a fundamental transformation in how they control and optimise their operations. Software-defined automation — with virtual controllers and edge computing — now offers a compelling idea: that it will be possible to dynamically configure automation infrastructure to align with strategic business objectives. The convergence of IT and OT will continue to deepen, with software-defined automation becoming the cornerstone of sustainable and efficient industrial operations, notwithstanding the inherent cybersecurity risk that must be mitigated in parallel.

Speaking of networks, this month we also have a bit of a primer on how Ethernet SPAN ports — an integral part of many switches — can be used to unobtrusively monitor and analyse industrial network traffic, just as it has been done in IT networks for some time, expanding the possibilities in relation to the use of cybersecurity tools.

Until next time…

Glenn Johnson Editor pt@wfmedia.com.au

INDUSTRY NEWS

DroneShield announces significant expansion in Europe

Australian defence manufacturer DroneShield has announced it is making a significant investment to expand its operations in Europe and support the continent’s domestic defence programs such as ReArm Europe Plan/Readiness 2030.

The counter-drone (CUAS) technology company is working to establish a European manufacturing and in-house assembly facility — its first outside of Australia. The expansion includes plans to establish a new sales hub and create a second manufacturing line for select DroneShield hardware, with at least 65% European-based industry content for certain products sold in the region. Europe is currently one of DroneShield’s largest geographical segments, with over $500 million across dozens of opportunities.

The expansion comes as Europe enacts its €800 billion (~AU$1.4 trillion) ReArm Europe Plan/Readiness 2030 plan to become more militarily self-reliant and counter the threat from Russia. DroneShield’s technology and devices continue to play a major role in supporting Ukraine in the Russia-Ukraine War.

Yokogawa celebrates 50 years of CENTUM with next-gen release

Hot on the heels of celebrating the 50th anniversary of the world’s first distributed control system launched on 19 June 1975, Yokogawa Electric Corporation has announced the unveiling of its 10th generation Release 7 concept and the launch of Release 7.01 of the CENTUM VP integrated production control system, a core product in the OpreX Control and Safety System range.

Yokogawa says it has based its development of CENTUM VP Release 7 on the concept of enabling autonomous operations, aiming to help its customers attain sustainability by improving energy efficiency, accelerating decarbonisation, and providing a safe and secure working environment.

Since its launch in 1975, more than 30,000 CENTUM systems have been deployed in more than 100 countries around the world, supporting a wide range of industries such as oil refining, petrochemicals, specialty chemicals, textiles, steel, pharmaceuticals, food, water, electric power and gas.

Hazer’s Japanese collaboration achieves first milestone

Hazer Group Ltd has announced progress on a planned Hazer production facility in Nagoya, Japan. The project is being developed in collaboration with Chubu Electric Power Company, a major Japanese energy utility, and global engineering company Chiyoda Corporation.

The planned project will utilise Hazer’s proprietary methane pyrolysis technology, under a licence agreement, and is initially designed to produce 2500 tonnes per annum of clean hydrogen along with high-quality graphite. The project will leverage and integrate with Chubu Electric’s existing LNG supply chain and infrastructure in the Nagoya region. The facility is designed as a scalable platform with potential to expand in response to growing demand for clean hydrogen and graphite.

Chubu Electric and Chiyoda have now successfully completed the pre-feasibility study and the project has advanced with the identification of a preferred site location, initial design and engineering activities, with the companies satisfied that the technology is cost-competitive and delivers favourable project economics.

DroneShield

Yokogawa Electric Corporation

Senior members of the National Diet of Japan, DFAT and Mitsui visited Hazer’s Commercial Demonstration Plant.

FROM

SMART TO VULNERABLE THE HIDDEN COSTS OF THE DIGITALISATION OF UTILITIES

Glenn Johnson, Editor

For Australia’s critical infrastructure sectors proactive investment in cybersecurity is no longer optional.

The control systems of Australia’s critical infrastructure utilities are becoming increasingly digitalised. While the aim is to improve efficiency and reliability, increasing digitalisation and connectivity also introduces significant cybersecurity vulnerabilities. Such critical infrastructure — our water, wastewater, and energy utilities — underpins the health, security, and economic prosperity of the nation, making cybersecurity vulnerabilities a risk to the community.

A major wakeup call occurred in 2020, when the Australian Government issued a warning of sustained cyberattacks on Australian networks, attributed to a “sophisticated state-based actor”, which it said “represents the most significant, coordinated cyber-targeting against Australian institutions the Australian Government has ever observed.”1 Since then, Australia has introduced and passed amendments to the Security of Critical Infrastructure (SOCI) Act, which now mandates increased security obligations for entities in these sectors2

CYBERSECURITY A MULTI-FACETED CHALLENGE

The rising threat landscape: nation-state and criminal activity

The cyberthreat landscape is evolving rapidly. Nation-state actors, cybercriminal groups, and hacktivists are increasingly targeting critical infrastructure, raising a number of challenges for critical infrastructure organisations.

In 2021, the Colonial Pipeline ransomware attack in the US reverberated globally, highlighting how vulnerable energy infrastructure can impact fuel distribution and economic stability. Closer to home, Australian utility providers have also faced real-world incidents. In October 2022, EnergyAustralia confirmed that attackers accessed customer accounts using compromised credentials, though no operational impact was reported3. In another case, South East Water disclosed efforts to increase cybersecurity protections following heightened threat activity4

State-sponsored actors often perform reconnaissance within critical infrastructure systems, prepositioning malware that can be activated during times of conflict5

The Australian Signals Directorate (ASD) has warned that geopolitical tensions in the Indo-Pacific may elevate the risk of disruptive cyber operations targeting Australia’s critical services.

The IIoT and smart infrastructure: a double-edged sword

As utilities modernise to improve services and reduce emissions, the IIoT is helping to transform how utilities operate. Smart meters and intelligent energy distribution devices enable better demand management and cost control. However, they also expand the attack surface considerably; poorly secured IIoT devices are often deployed without strong authentication or firmware validation. In some cases, vendors use hard-coded passwords or leave services open to the internet. Once compromised, these devices can serve as entry points into larger OT networks or even be harnessed into botnets.

The Australian Energy Market Operator (AEMO) has also highlighted growing concerns about cybersecurity in distributed energy resources (DER), such as home solar systems and battery storage, which are increasingly interfaced with grid management platforms6. Recent revelations7 that Chinese-made solar inverters, batteries and other related technologies have been compromised by ‘rogue’ communications technologies also raises questions about just how pervasive the threat is among technologies being added to the distributed electricity grid.

Supply chain and third-party risks

Utility operators rely heavily on contractors, service providers, and third-party vendors for software, hardware, and maintenance. Each third-party connection introduces a potential point of compromise.

According to the ACSC, Australian utilities need to adopt stronger procurement practices, such as vendor security assessments, contractual obligations for incident disclosure, and mandatory multifactor authentication for contractor access8

The problem of aging infrastructure

Australia’s utility providers often rely on legacy operational technology (OT), such as SCADA systems and PLCs, which were designed decades ago with minimal consideration for cybersecurity. The designers and operators of such systems assumed that physical isolation (air gapping) was a sufficient defence.

However, modernisation efforts, including remote monitoring, predictive maintenance, and integration with enterprise IT networks – as well as the Industrial Internet of Things (IIoT) — have introduced new pathways for cyber threats. Many legacy ICS environments now operate with ‘bolted-on’ rather than ‘built-in’ security features, which are often poorly configured due to resource constraints. For example, remote water treatment facilities in regional areas may rely on 4G connections with weak or default credentials, making these systems susceptible to basic cyberattacks such as credential stuffing or port scanning.

Resource gaps and skill shortages

Another persistent challenge for many Australian utilities, especially in rural and regional areas, is the lack of in-house cybersecurity expertise. Smaller utilities often do not have dedicated security teams and may outsource IT functions entirely. This leads to inconsistent patching practices, limited threat detection capabilities, and slower incident response times.

According to the ACSC’s Annual Cyber Threat Report (2023)9, there were over 1100 cyber incidents affecting critical infrastructure sectors in the previous year, yet only a fraction of these were reported in a timely manner. Meanwhile the cybersecurity workforce gap in Australia is increasing, with high competition for skilled OT security professionals. Additionally, many field technicians and engineers who manage ICS environments may be unfamiliar with cybersecurity best practices, increasing the risk of social engineering attacks such as phishing or USB baiting.

Detection and incident response gaps

It is well known in the process control and automation industries that traditional IT security tools often do not work well in OT environments: a routine virus scan or update may inadvertently cause a PLC to reboot, halting operations. This means many ICS environments operate with limited visibility into real-time threats.

Most small and mid-sized utilities in Australia also do not have Security Operations Centres (SOCs) or Security Information and Event Management (SIEM) systems tailored for ICS protocols. Tools like intrusion detection systems (IDS) must be calibrated for Modbus, DNP3, or IEC 61850, yet these solutions are costly and require skilled personnel to operate.

Incident response planning can also often tend to be underdeveloped. Utilities may not conduct regular tabletop exercises or have coordinated response agreements with local law enforcement or emergency services.

ADDRESSING THE CHALLENGE

The SOCI Act and mandatory reporting To address growing threats, Australia has strengthened its regulatory approach. The SOCI Act now applies to 22 asset classes over 11 sectors, including water and energy, and imposes obligations in four key areas:

• Asset registration

• Incident reporting Risk management programs

• Government intervention powers Failure to comply with the requirements of The SOCI Act can result in significant penalties, including fines or enforcement actions. Understanding these compliance requirements is crucial for organisations to effectively navigate their cybersecurity and supply chain obligations. In addition, the regulatory landscape is evolving and it is incumbent on critical infrastructure organisations to keep abreast of any future amendments.

The Cyber and Infrastructure Security Centre (cisc.gov.au) provides guidance and sector-specific templates to assist.

Recommendations for strengthening resilience

To address the multifaceted cybersecurity challenges faced by today’s utilities, a layered and collaborative approach is necessary. Cybersecurity experts tend to list the following recommendations as a guide:

• Maintain asset visibility: Keep detailed, continuously updated inventories of hardware and software in ICS environments.

• Utilise network segmentation: Use firewalls and VLANs to separate IT from OT systems and limit lateral movement in the event of a breach.

• Enforce strict access controls: Enforce multi-factor authentication (MFA) for all remote access, especially to SCADA systems.

AS IF THE EXISTING CYBERSECURITY CHALLENGES FOR UTILITIES WERE NOT ENOUGH, WE NOW SEE ANOTHER CYBERSECURITY THREAT LOOMING OVER THE HORIZON: QUANTUM COMPUTING.

• Provide staff training: Regular cybersecurity awareness training should be given to engineers, plant operators and IT personnel.

• Work diligently on patch management: Develop procedures to test and apply updates in ICS environments without disrupting operations.

• Adopt recommended frameworks: Align with international standards such as the NIST Cybersecurity Framework, IEC 62443, and ISA/IEC 99 for industrial security.

• Government partnerships: Engage with government agencies for threat intelligence and best practices.

• Invest in monitoring: Deploy OT-aware detection and response tools to identify anomalies early and reduce incident response time.

QUANTUM COMPUTING: THE

CYBERSECURITY THREAT ON THE HORIZON

As if the existing cybersecurity challenges for utilities were not enough, we now see another cybersecurity threat looming over the horizon: quantum computing.

Research into quantum computing is progressing rapidly — with companies like Google and Microsoft having already announced they have developed quantum computing chips — and while this new technology is still in its developmental phase, it promises to revolutionise many aspects of computing. However, one of the most disruptive effects will be its ability to break current cryptographic standards, particularly public-key encryption methods such as RSA, DSA, and ECC. These encryption methods underpin everything from secure logins and VPNs to the authentication of industrial control system communications.

The implications for critical infrastructure are profound. Most SCADA and ICS systems use asymmetric encryption to secure communication and firmware updates. A sufficiently powerful quantum computer could decrypt sensitive configuration files, forge updates, or impersonate legitimate controllers, potentially allowing an attacker to manipulate operations remotely. Utilities also depend on digital certificates to authenticate devices and users, and quantum computing could render these certificates useless unless post-quantum cryptographic algorithms are adopted.

It may be quite some time until the average criminal hacker can acquire quantum computing to crack encryption, leaving nation-state actors the only one who may be able to afford such technology. However, as geopolitical tensions rise in the Indo-Pacific, nation-state adversaries are expected to prioritise quantum readiness. Water and energy utilities, often the soft underbelly of national infrastructure, may be targeted to cause mass disruption without triggering military escalation.

Quantum-powered cyberattacks, when they arrive, are likely to be selective and strategic — targeting authentication systems, secure firmware channels, or encrypted remote telemetry links used in water pumping stations and electrical substations.

Australia’s SOCI Act is expected to evolve further to include guidance or mandates on post-quantum cryptography (PQC) in the years ahead. International frameworks (such

as the US NIST Post-Quantum Cryptography project) are developing new standards, and Australian utilities will need to align to maintain international interoperability and compliance.

However near or far in the future these developments may be, the time to be concerned is actually the present. Even today, attackers may harvest encrypted data and traffic with the intent to decrypt it in the future using quantum computers (the ‘store now, decrypt later’ strategy). Sensitive operational data, intellectual property and SCADA configurations therefore need to be protected from harvesting now, making current cybersecurity measures all the more important.

While large-scale, practical quantum computers may still be several years away, the threat is not theoretical. For Australia’s water, wastewater, and energy utilities — sectors already under constant cyber threat — quantum computing represents a new paradigm of risk.

Recommendations for utility operators

While the cybersecurity risks posed by quantum computing are still a future threat, steps need to be taken now to mitigate the future risk. The following steps should be under consideration:

• Inventory cryptographic assets and assess where quantum-vulnerable algorithms are used, especially in remote sensing and control devices.

• Begin planning for crypto-agile architectures — systems that can adapt

to future algorithm changes without complete hardware replacement.

• Work closely with government agencies like the Australian Cyber Security Centre (ACSC) and Australian Signals Directorate (ASD) to align with national quantumreadiness strategies.

• Encourage vendor accountability by requiring post-quantum readiness in new product procurements.

CONCLUSION

Australia’s critical infrastructure sectors are facing a cybersecurity crossroads. As the digitalisation of water and energy utilities accelerates, so too does their exposure to sophisticated cyber threats. With aging assets, tight budgets and increasing regulatory complexity, proactive investment in cybersecurity is no longer optional — it is essential.

1. Australian Cyber Security Centre 2020, Advisory 2020-008: Copy-Paste Compromises - tactics, techniques and procedures used to target multiple Australian networks

2. Department of Home Affairs 2022, Security Legislation Amendment (Critical Infrastructure Protection) Act 2022

3. Energy Source & Distribution 2022, Customer details exposed in EnergyAustralia cyberattack

4. Castlepoint Systems 2021, South East Water: PII discovery project defends against increased cyber threats

5. Australian Cyber Security Centre 2023, ASD Cyber Threat Report 2022-2023

6. Australian Energy Market Operator 2022, Australian Energy Sector Cyber Security Framework (AESCSF) Overview

7. McFarlane S 2025, Rogue communication devices found in Chinese solar power inverters, Reuters

8. Australian Cyber Security Centre 2025, Guidelines for procurement and outsourcing

9. Australian Cyber Security Centre 2023 (n 5)

INDUSTRY NEWS

Drone Forge to deliver the first turnkey drone fleet in Australia

Australian startup Drone Forge has announced it has commenced packaging what it says is the world’s first turn-key fleet of drones.

The fleet, DF Fleet 1, is estimated to begin delivery in 2026 and will offer direct exposure to a new and globally sought-after asset class.

“The drone market has evolved rapidly and this has highlighted the need for mature asset management solutions that give direct and diversified exposure to the global drone opportunity,” said Thomas Symes, Founder and Chief Executive Officer of Drone Forge.

“The market does not need more drones: it needs a company that can enable, support and scale customers,” Symes said. “By packaging a turn-key fleet for institutional investors and large-scale operators, we’re not only making drone technology more accessible, but enabling operators across a diverse range of industries to take advantage of the latest unmanned aerial systems.”

Detmold Group to build new global HQ in Adelaide

Australian-owned international packaging company, Detmold Group, has announced it is constructing a new global corporate and manufacturing headquarters at Regency Park, South Australia.

The Detmold Group is a family-owned and operated business, and operates in 17 countries with manufacturing facilities in seven.

The three-level, 3,500 m2 facility will accommodate up to 240 employees, with staff from eight sites across Adelaide metropolitan suburbs Brompton, Hindmarsh and Regency Park consolidating under one roof by the end of 2026.

Detmold Group CEO Sascha Detmold Cox said the Group’s new headquarters in Regency Park represented a strategic investment in the future of the Detmold Group.

“Purpose-built with sustainability, collaboration and employee wellbeing in mind, our new corporate home integrates contemporary design with environmentally-responsible solutions and an openplan layout that supports collaboration and innovation,” she said. “Bringing our Detmold family under one roof will help foster stronger connections, knowledge sharing, and a unified culture aligned with our core values.”

Government awards $16.5 million in grants for defence manufacturing

The federal government has announced that grants have been awarded to more than 50 businesses across the country that provide priority defence capabilities.

The first rounds of the Defence Industry Development Grants program have been completed, with 58 grants worth $16.5 million awarded to Defence suppliers in four streams: export, skilling, security and sovereign industrial priorities.

More than 200 employees in defence businesses will receive new technical training through the skilling stream of the program. Several businesses will uplift their physical, personal and cybersecurity posture to meet Defence security requirements through the security stream of the program.

Four businesses in South Australia, Queensland, Western Australia and Victoria were awarded grants of $1 million to directly support manufacturing under the sovereign industrial priorities stream, including components used in submarines, aerospace, guided weapons and explosive ordnance projects.

SERVO DRIVES

Italian motion control manufacturer CMZ Sistemi Elettronici has a standalone servo drive for brushless motors from 0.7 to 7 kW.

LAPP Australia Pty Ltd

RADAR SENSORS

Pilz has introduced two updated models to the PSENradar range, leveraging FMCW radar technology operating at 24 GHz.

Pilz Australia Industrial Automation LP

IO-LINK HUBS

Pepperl+Fuchs has expanded its IO-Link hub range with the G11 and G16 series Class A devices.

Pepperl+Fuchs (Aust) Pty Ltd

ARM-BASED PANEL PC

Advantech has announced that its ARM-based TPC-100W series panel PC has achieved ARM SystemReady IR certification.

Advantech Australia Pty Ltd

HOT PRODUCTS

NEWPRODUCTS

PHASE IDENTIFICATION SYSTEM

DEWESoft has introduced GridPhase, a phase identification system designed to bring precision and efficiency to phase tracking across high- and low-voltage distribution networks.

GridPhase is a GPS-synchronised, handheld phase identification tool that enables field technicians, electricians and utility crews to determine which phase they are working on — even across transformer vector groups and large geographic areas. Combined with the GridPhase Reference Device and GridPhase Web platform, the system is designed to deliver an end-to-end solution for phase mapping, network maintenance and load balancing.

The handheld phase identification tool is a GPS-synchronised, Bluetooth-enabled device that pairs with a mobile app to display live phase angle, frequency, voltage readings and labels (A/B/C). A DIN rail-mountable reference device is installed at a known location (eg, a substation) to serve as the system’s phase angle baseline.

Web integration through the GridPhase Web platform allows central management of measurements, transformer compensation, and unified phase mapping across a network, while an automatic transformer phase shift compensation algorithm corrects for phase angle variations introduced by transformers, without the need for manual adjustment.

Applications include smart meter installation and commissioning, utility and DNSP network maintenance, load balancing and neutral current reduction, renewable energy connection mapping, and substation upgrades and DER integration, as well as the easy identification of phases in switchboards or fuse boxes.

Metromatics Pty Ltd www.metromatics.com.au

LONG-RANGE INDUCTIVE PROXIMITY SENSORS

Most inductive proximity sensors offer contactless detection at short range. Leuze has now released the IS 200 series inductive sensors that enable switching distances of up to 40 mm in compact, cylindrical housings. Suitable for applications with small installation spaces, larger distances, or for machine concepts with larger tolerances, they also detect imprecisely placed metallic objects and minimise collision risks during operation.

The IS 200 series sensors are available in cylindrical M12, M18 and M30 housings made of nickel-plated brass. Leuze offers each sensor type in two mounting variants, for quasi-embedded and non-embedded installation. The sensors offer users the advantage of detection for moving machine components, as well as tools, input materials or end products made of steel, aluminium, copper alloy or stainless steel. The large switching distance means one compact sensor model can be used for several operating ranges. This standardisation therefore also reduces storage costs and helps maintain a cost-efficient system design.

The devices in the IS 200 series fulfil the requirements of protection class IP 67, and operate in a wide temperature range from -25 to +70°C.

Leuze electronic Pty Ltd www.leuze.com.au

COLLABORATIVE ROBOT

Universal Robots has released the UR15, which it says is the company’s fastest ever cobot, enabling reduced cycle times. For pick-and-place applications, the UR15 is said to deliver up to 30% cycle time improvements compared to other UR models.

Combined with OptiMove, UR’s latest motion control technology, those gains are said to go further, enhancing trajectory smoothness and providing consistently accurate movements in high-speed and high-payload applications.

UR15 runs with both PolyScope 5 and PolyScope X software platform, and is AI-ready. The UR15 can easily be used with the UR AI Accelerator, UR’s toolkit for developing AI-powered applications. The UR AI Accelerator was developed in collaboration with NVIDIA using NVIDIA Isaac’s CUDA-accelerated libraries and models and running on the NVIDIA Jetson AGX Orin system-on-module.

The UR15 has a payload of 15 kg which can be increased to 17.5 kg for applications with wrist-down orientation, such as palletising.

Universal Robots www.universal-robots.com

Smart Sensor Technologies

NEWPRODUCTS

ATEX CABINET COOLER SYSTEMS

EXAIR’s ATEX Cabinet Cooler systems are designed to provide a solution for keeping electrical enclosures cool in hazardous ATEX classified areas, and are now available in aluminium construction. Engineered for use in Zones 2 and 22, the coolers are UL tested and CE compliant, and they meet stringent ATEX standards for purged and pressurised enclosures.

With cooling capacities up to 5600 BTU/h, ATEX Cabinet Coolers are designed for preventing overheating in electrical cabinets exposed to explosive atmospheres, whether industrial control panels, application-specific electrical boxes, or sensitive electronics in hazardous locations. Designed for quick and easy installation, the ATEX Cabinet Cooler mounts through a standard electrical knockout and maintains NEMA 4 (IP66) integrity. Optional thermostat control reduces compressed air usage, while cold air distribution kits help ensure even cooling throughout the cabinet.

Compressed Air Australia Pty Ltd www.caasafety.com.au

LINE PROTECTION MODULES

Pepperl+Fuchs has expanded its M-LB-2000 signal line protection system with the addition of the M-LB-2600 modules, specifically developed for 3-wire transmitters and sensors.

Housed in the same compact 6 mm design, these variants are designed to deliver enhanced protection and precision, particularly in applications where accuracy is critical. Compared to conventional 2-wire systems, 3-wire measurement offers a significant improvement in performance by eliminating the influence of line resistance on signal accuracy. In a 3-wire setup, three distinct circuits enable compensation for lead resistance, ensuring voltage drops along the connection cables do not distort the final measurement. This results in higher accuracy, greater stability and the ability to cover longer cable distances without compromising signal integrity.

The M-LB-2600 modules are available in eight new variants, offering flexible protection for a wide range of signals from or to both hazardous and non-Ex areas. From 24 V control signals to sensitive low-voltage applications such as temperature measurement, the modules support diverse topologies while helping to maintain performance and safety.

Pepperl+Fuchs (Aust) Pty Ltd www.pepperl-fuchs.com

MODULAR HMIS

Advantech has introduced the TPC-B300 and TPC-B520 to its modular HMI series, offering more than 30 flexible configurations with screens from 12 to 24 inches. Featuring a sleek dark blue design, these solutions are designed to enhance industrial operations with customisable CPU and I/O options.

Advantech’s modular approach aims to accelerate product development and delivery, providing stability, extended lifecycles and simplified upgrades. With the latest CPUs, these HMIs are said to minimise downtime and costs, making them suitable for modern industrial applications.

Built for harsh environments, the TPC-B series features a fanless design, TPM 2.0 security and multiple mounting options (panel, wall, stand and VESA). Supporting Windows 10/11 LTSC and Advantech Linux, the TPC-B520 offers high computing power, while the TPC-B300 provides a compact, power-efficient alternative.

Available in 12–23.8” sizes, these IP66-rated P-CAP multitouch screens operate in -20 to 60°C environments. Select models (12”, 15”, 15.6” and 21.5”) also offer high-brightness options for outdoor use.

Suitable for MES workstations, production lines and equipment manufacturing, these HMIs support Profinet, Profibus and EtherCAT, and integrate with WebAccess/SCADA and HMINavi.

Advantech Australia Pty Ltd www.advantech.net.au

INDUSTRIAL ETHERNET SWITCHES

Belden has announced the launch of its Hirschmann GREYHOUND2000 standard switch, which is designed to deliver high fibre port density and offers configurable port modules that make it adaptable to various connectivity scenarios.

These rugged switches are designed for a wide range of markets and applications. GREYHOUND2000 is suitable for power generation, transmission and distribution and within the process industries.

With up to 34 ports the GREYHOUND2000 offers the most of any Belden rugged industrial Ethernet switch. Redundancy protocols are also built into every port to help enable the high uptime and network stability required by mission-critical operations. The switches are also designed for tough industrial environments with a wide operating temperature range of up to +85°C for 16 hours in dry heat and high electromagnetic compatibility. High uptime and network stability is improved with support for Precision Time Protocol (PTPv2), hardware prepared for Parallel Redundancy Protocol (PRP) and HighAvailability Seamless Redundancy (HSR) protocol.

Belden Australia Pty Ltd

SOFTWARE-DEFINED AUTOMATION POWERING THE NEXT GENERATION OF PROCESS INDUSTRIES

Axel Lorenz*

The process industries are experiencing a fundamental transformation in how they control and optimise their operations, marking one of the most significant shifts in industrial technology in decades.

Today the process industries operate in an increasingly complex environment where an aging infrastructure is being confronted with modern digitalisation demands. Many plants maintain systems that have been in service for over three decades, often resulting in data silos and operational inefficiencies. Organisations frequently manage varying levels of automation across different locations, even within the same company, while facing pressure to integrate modern digital capabilities. The system landscape in process plants ranges from simple applications to complex, highly integrated safety solutions and precisely validated plants. Data silos are increasingly common in industries that rely on plants that have existed for years. Despite these challenges, many technological innovations have been developed to help upgrade older process control technologies. However, this requires an understanding of the installed system base of process industry manufacturers.

DECOUPLING OF HARDWARE AND SOFTWARE ENABLES A FLEXIBLE MODIFICATION OF OPERATIONS

Software-defined automation (SDA) addresses the aforementioned issues by providing the ability to integrate data flows and dynamically control systems with no need for extensive hardware modifications. Decoupling hardware and software components to enable more flexible and efficient industrial operations represents a significant evolution in process control systems. This approach addresses current challenges in the process industries while preparing organisations for future technological advances. However, the true potential of SDA lies not just in its technical capabilities but also in how it aligns with and supports broader business strategies.

Software-defined automation fundamentally changes how process control systems operate. According to this new concept, the traditional automation pyramid is being altered to a more dynamic network architecture that enables a real-time data

flow between field devices and higher-level systems through Industrial Internet of Things (IIoT) technologies, digital twins and edge computing. Perhaps most significantly, this new architecture enables the breakdown of traditional data silos by combining information from various sources to create comprehensive digital systems that support real-time, data-driven decision-making.

SMART IIOT SENSORS SUPPORT DATADRIVEN PRODUCTION OPTIMISATION

Software-defined automation is supported by a confluence of advanced technologies that collectively drive its transformative capabilities. At the heart of this approach is edge computing, which brings computation and data storage closer to the data source. This proximity minimises latency and bandwidth use, while facilitating the real-time processing and immediate responsiveness that is essential for industrial operations. Coupled with IIoT, SDA leverages smart sensors to collect vast amounts of data from diverse sources across the production environment. These sensors

feed into robust data networks that support a seamless interaction between operational technology (OT) and information technology (IT), breaking down the barriers of traditional data silos.

The cloud infrastructure further amplifies SDA’s potential by offering scalable computing resources for comprehensive data analysis and long-term storage solutions. This blend of technologies ensures that process industries can do more than enhance their operational efficiency — they can also harness valuable insights through predictive analytics and smart decisionmaking processes. The strategic deployment of these technologies lays the cornerstone for successful SDA, enabling a new level of flexibility and operational optimisation.

VIRTUAL CONTROLLERS OFFER A NEW APPROACH TO OPERATIONAL CONTINUITY

The recent emergence of virtual controllers signifies another paradigm shift in process automation by offering new possibilities for flexible and scalable control architectures. While hardware-based control systems have been the backbone of the process industries for decades, virtual controllers are now being developed that promise to enable more dynamic and adaptable automation solutions. These software-based control entities are intended to emulate

traditional hardware controllers, while adding capabilities for rapid reconfiguration, remote management and enhanced integration with other digital systems. However, their implementation follows a nuanced approach in process manufacturing. In critical processes — for instance, in oil and gas operations — robust hardwarebased components with established safety standards remain essential. The future lies in hybrid architectures where virtual controllers complement rather than completely replace traditional hardware systems.

The transition to software-defined automation doesn’t require a complete system overhaul, which makes it accessible even for plants with decades-old infrastructure. With a strategic approach to brownfield modernisation, process manufacturers can implement softwaredefined solutions while preserving their existing hardware investments. This ‘evolution over revolution’ strategy employs minimally invasive upgrades and modular concepts that allow plants to maintain operational continuity, while gradually breaking down traditional data silos. For example, companies can selectively upgrade specific plant areas that promise the greatest immediate value, using open interfaces to integrate legacy systems with modern software solutions. The key lies in choosing

modular solutions that can interface with existing systems, while providing a clear pathway to future capabilities. This ensures that each modernisation step adds value without disrupting critical operations.

MODIFYING AUTOMATION FOR NEW BUSINESS STRATEGIES

Software-defined automation offers a compelling value proposition: it enables process industries to dynamically configure their automation infrastructure to align with their strategic business objectives. This means that the architecture of production systems should be determined by an organisation’s core business strategy rather than technical constraints alone. This turns automation into a service that covers the entire user experience, from engineering to operation. Users can decide for themselves when, where and how they want to use the services — at the edge, in the cloud or onsite — and who will use them. This allows automation to be integrated much more deeply into the extended ecosystem of a production facility, regardless of its location or organisational affiliation. For instance, in the pharmaceutical industry, contract manufacturers might view plant optimisation as their core competency, while large integrated pharmaceutical companies may prefer to focus on product development rather than optimising plant operations. The latter could choose to outsource plant optimisation to specialists like system integrators and maintain oversight through key performance indicators.

This flexibility in implementation reflects a fundamental principle: let the experts be experts, but maintain strategic control over business decisions. Organisations can purchase the necessary services based on their strategic needs, though this approach requires finding the right partners with the appropriate domain expertise. For contract manufacturers, the key difference lies in their ability to optimise plant operations and deeply understand the processes. This encompasses critical process parameters and quality attributes, especially in industries like pharmaceuticals, where translating this kind of knowledge into automation language and continuous optimisation is crucial.

CYBERSECURITY BECOMES INDISPENSABLE

As systems have become more connected, cybersecurity has emerged as a critical component of software-defined automation

implementation. SDA requires robust security protocols in order to maintain the desired level of connectivity and data sharing. In the connected industrial landscape, cybersecurity is essential for the digital transformation. For instance, many organisations rely on the defence-in-depth concept, which follows the recommendations of IEC 62443 and provides protection at all levels. The convergence of IT and OT demands a holistic approach to security that takes into account the specific requirements of both areas.

Industrial companies are advised to consider network and automation components with integrated security features — along with the corresponding security services for implementing multi-layered security concepts — when transforming their production into a digital enterprise.

OPEN INTEGRATION OF CLOUD TECHNOLOGIES ENABLES AI-BASED COPILOTS

The evolution of process control technology continues to accelerate, with an increasing integration of artificial intelligence (AI) and cloud-based solutions. Recent developments include AI-based copilots for automated sequence function creation, cloud-based engineering environments that enable global collaboration, enhanced security features, and Good Manufacturing Practice (GMP) capabilities.

Organisations that are considering software-defined automation should assess their current automation infrastructure,

SOFTWARE-DEFINED AUTOMATION OFFERS A COMPELLING VALUE PROPOSITION: IT ENABLES PROCESS INDUSTRIES TO DYNAMICALLY CONFIGURE THEIR AUTOMATION INFRASTRUCTURE TO ALIGN WITH THEIR STRATEGIC BUSINESS OBJECTIVES.

identify specific operational challenges, develop a phased implementation strategy, consider both immediate needs and future scalability requirements, and evaluate the cybersecurity implications — all while ensuring alignment with their overall business strategy.

SIMULATION AND DIGITAL TWINS FOR IMPROVED COLLABORATION AND FASTER TIME TO MARKET

The evolution of software-defined automation is being driven by technological advances and changing industry demands. Artificial intelligence is becoming increasingly democratised in industrial settings, with AI-powered copilots emerging as valuable tools for a variety of use cases in the engineering and operations space. AI assistants are helping engineers and planners with tasks ranging from basic sequence control to complex process simulations, which is making advanced automation capabilities accessible to a broader workforce.

Cloud-based engineering environments are facilitating unprecedented levels of global collaboration by allowing teams to work seamlessly across different locations while maintaining consistent standards. The integration of simulation tools is moving toward allowing rapid testing and validation of process changes without risking physical assets. This development is particularly significant because it permits organisations to continuously optimise their processes while minimising downtime and risks.

IT/OT CONVERGENCE WILL HELP DRIVE SUSTAINABILITY

Looking ahead, the convergence of IT and OT will continue to deepen, with software-defined automation becoming the cornerstone of sustainable and efficient industrial operations. Advanced technologies like digital twins, edge computing and AI-driven analytics will become standard components of automation infrastructure, and this will enable more predictive and prescriptive operational models. As these technologies mature, we can expect to see an increased focus on sustainability initiatives, with automation systems playing a crucial role in optimising resource usage and reducing environmental impacts.

As the industrial landscape continues to evolve, organisations need to take proactive steps to prepare for a software-defined future. Success in this transformation requires a balanced approach that combines strategic vision with practical implementation. Companies should begin by assessing their current automation infrastructure and identifying areas where software-defined solutions can deliver immediate value, while developing a clear roadmap for a longer-term transformation. The shift to software-defined automation isn’t just a technical upgrade — it’s a fundamental reimagining of how industrial operations can be more agile, efficient and sustainable. Those who embrace this change while taking a measured, strategic approach to implementation will be ideally positioned to thrive in an increasingly dynamic and competitive global market.

*Axel Lorenz is the CEO of Siemens Process Automation. Prior to this leadership role, he has held many different management, engineering and automation roles at Siemens over his more than threedecade career. He holds a BS in Electrical Engineering from Berlin University of Applied Sciences.

TACKLING THE EVOLVING CYBER CHALLENGES IN OUR INDUSTRIAL SECTOR

Australia’s manufacturing, processing and mining industries are cornerstones of the economy, and heavily reliant on instrumentation, process control and automation systems to drive operational efficiency. These operational technology (OT) environments, however, face escalating cybersecurity risks as they become more interconnected with IT systems and external networks, requiring organisations to introduce robust cybersecurity measures to secure them.

THE GROWING THREAT LANDSCAPE

The 2023–24 Annual Cyber Threat Report highlighted a 13% increase in cyber incidents targeting critical infrastructure, with manufacturing and mining among the most affected. Legacy OT systems, often designed without security in mind, are particularly vulnerable. For instance, unpatched HMIs or PLCs can serve as entry points for attackers.

Recent examples underscore the real-world impact of these threats. A 2020 ransomware attack on a major Australian manufacturer saw local wool and dairy deliveries brought to a halt. In 2021, an attack on one of the world’s largest meat processors left Australian grocery stores with bare shelves.

As OT environments increasingly adopt IoT devices and cloudbased solutions, their attack surface expands, necessitating proactive cybersecurity strategies.

COLLABORATION BETWEEN OT OWNERS AND CYBERSECURITY STAKEHOLDERS

A close working relationship between the owners of process control networks — engineers and operators managing OT systems — and cybersecurity stakeholders, including IT security teams and third-party consultants, is essential for securing industrial environments. Historically, OT and IT teams operated in silos, with differing priorities: OT focused on uptime and safety, while IT emphasised data security. This disconnect can lead to misaligned security policies, leaving gaps in protection. For example, OT engineers might prioritise system availability over applying a security patch, inadvertently exposing the network to exploits.

In Australia, fostering collaboration is critical to bridging this gap. Regular cross-functional workshops, joint risk assessments and shared governance models can align objectives. For instance, integrating OT-specific threats into enterprise-wide security operations centres (SOCs) ensures real-time threat detection without compromising operational continuity. Companies like BHP have implemented such models, embedding cybersecurity experts within OT teams to enhance threat response. This collaborative approach ensures that security measures respect the unique constraints of OT environments, such as avoiding downtime during production cycles.

THE CRITICAL ROLE OF ASSET INVENTORY

An accurate, up-to-date asset inventory is the foundation of effective OT cybersecurity. Without a clear understanding of all devices, software

and connections within a process control networks, organisations cannot identify vulnerabilities or prioritise mitigation efforts. In Australia’s mining sector, sprawling operations with legacy and modern systems often lack comprehensive asset visibility. A 2022 ACSC report noted that 60% of critical infrastructure operators struggled to maintain complete asset inventories, hindering incident response.

Implementing automated asset discovery tools can address this challenge. These tools map OT networks, identifying devices like PLCs, SCADA systems and IoT sensors, while cataloguing firmware versions and network dependencies. By maintaining a dynamic inventory, organisations can prioritise patching, segment networks and detect anomalies, significantly improving cybersecurity outcomes.

SECURE ACCESS METHODS FOR MODERN OT ENVIRONMENTS

Secure access to OT networks is another critical pillar of cybersecurity, but traditional methods like shared credentials or unencrypted remote access are no longer sufficient. The rise of remote operations in mining and manufacturing, accelerated by the COVID-19 pandemic, has increased reliance on remote access for maintenance and monitoring. However, weak access controls are exposing these OT systems to external threats. The 2021 Colonial Pipeline attack in the US, though not Australian, highlighted how compromised remote access can cripple operations.

Modern OT environments require secure access solutions like Zero Trust Architecture (ZTA) and multi-factor authentication (MFA). ZTA verifies every access attempt to the process control network, regardless of location, reducing the risk of unauthorised entry, while MFA adds additional layers of protection, ensuring that even stolen credentials cannot be easily exploited. Australian firms are increasingly adopting these methods, with one WA mining company reducing unauthorised access attempts by 80% after implementing ZTA in its SCADA systems.

CONCLUSION

Australia’s instrumentation, process control and automation industries face a complex cybersecurity landscape, driven by digital transformation and evolving threats. By fostering collaboration between process control network owners and cybersecurity stakeholders, maintaining comprehensive asset inventories and implementing secure access methods, organisations can significantly enhance OT security.

Leon Poggioli is Regional Vice President ANZ at Claroty, a technology company focused on cybersecurity for industrial and healthcare environments. In his role, Leon is committed to protecting Australian organisations against cyber attacks, particularly the critical infrastructure that keeps our nation running.

World-first Australian solution to treat wastewater at a major beverages company

Australian innovator Products For Industry (PFi) is introducing what is believed to be a world-first pure titanium cross-flow membrane solution, which has uptime, environmental and yield benefits compared to traditional wastewater treatment methods.

After more than 10 years of development, a fully evolved and tested product is now entering service in Australia with a leading beverages company, which will use the new technology to separate solids from liquid streams in various stages of the waste stream process.

PFi is a locally owned and operated business servicing the industrial sector, offering a full suite of in-house capabilities to support manufacturers with machine automation products, systems and solutions, from concept through to production.

“This solution is game-changing for the food and beverage industry, particularly beverages and spirits, because titanium allows for a lower footprint, and longer times between clean-in-place (CIP), thereby reducing downtime,” said PFi managing director Gavin Dunwoodie. “With traditional membranes made of ceramic or plastic, back-pulsing and cleaning often creates problems, so the overall lifetime of the equipment is reduced.”

Titanium (Ti) is the ninth most known metal in the Earth’s crust and possesses the highest strength-to-weight ratio. It is as strong as steel, but weighs 45% less, and is non-magnetic, non-corrosive and does not conduct electricity.

“This forward-thinking beverages company wanted an advanced solution that would continue to increase their throughput, while lowering their environmental footprint. They were clear from the outset that there should be no compromises on quality,” Dunwoodie said.

“What we needed was automation hardware that was streamlined, repeatable and easy to integrate, so we selected Rockwell Automation’s CompactLogix Control System and PanelView Plus Graphic Terminal. These provided us with an integration that would be accepted by global leaders like this beverages company,” he added.

PanelView Plus provides the graphical interface through a seamless integration with the CompactLogix Controller. This integration enables engineers to enter configuration information once and use it for the entire automation design. It also helps build modern applications with high-speed HMI buttons for jogging applications, scalable vector graphics and a pre-configured system banner that provides diagnostic information.

“Rockwell worked with us to select the best hardware for the job, made sure it was fit for purpose, and supported us along the way,” Dunwoodie said. “Additionally, the customer specified that the coding style needed to be PAC-ML, an internationally recognised standard, so Rockwell set up its technologies to match this need.”

Rockwell Automation regional director, South Pacific, Anthony Wong said: “We are delighted to be able to provide automation technology solutions, and ongoing support for PFi’s latest Australian innovation.”

To develop the titanium cross flow membrane solution, PFi built a new factory on its existing site in Queensland.

“We conducted extensive pilot tests at a wastewater treatment plant in New Zealand three years ago, where we found the titanium solution allowed very high flow and flux rates, easy and fast CIP, and no fouling or long-term issues with fats, oils and greases. It also showed us that

running costs and energy use would be reduced over the system’s lifetime, and the titanium membrane can be recycled at the end of its use in the solution,” Dunwoodie said. “We also appreciate the support we received from the Australian Government, to help scale up and accelerate the success of this product, which has considerable local and export potential.”

With titanium’s natural advantages as a material, its use in a cross flow membrane comes with several advantages. A continuous length of more than 1.3 m is possible, along with a larger range of apertures and filtration sizes. Wall thicknesses below 400 µm are also possible, which PFi believes to be unique globally, providing high flux rates and flow levels through the membrane. Titanium also offers higher levels of resistance to temperature, acidity and pressure.

A titanium membrane is also back-pulsable, steam-cleanable and chemical resistant, and is cost-comparable with ceramic membranes that cannot be back-pulsed.

Dunwoodie sees great potential for this solution globally and is looking to scale up operations, after successful pilots and testing, and now in service with this beverages client.

“Rockwell’s standard design will help with our solution’s market acceptance when we enter the export market. There is particularly strong potential in the spirit industry, where it can replace paper membranes to deliver better outcomes with reduced waste,” he said. “Titanium provides a true closed loop solution, as the only 100% recyclable membrane, even after 20 or more years in service, which is an outstanding benefit to an end-user’s ESG goals.”

Rockwell Automation Australia www.rockwellautomation.com/en-au.html

NEWPRODUCTS

SAFETY LASER SCANNER

The RSL 200 from Leuze is a compact device designed to reliably safeguard machines, systems, automated guided vehicles and autonomous mobile robots. It offers an operating range of 3 m and a 275° scanning angle. For a greater operating range of up to 8.25 m, users can choose the RSL 400.

The configurable and switchable protective and warning fields of the RSL 200 enable flexible protection. They allow the monitored areas to be optimally adapted to curved paths, different speeds and various load conditions. Omnidirectional vehicles can be safeguarded in all directions with the laser scanner: only two diagonally mounted devices are required due to the 275° scanning angle. With 32 switchable sets of protective and warning fields, the speed and direction of travel can be continuously adjusted.

Ease of servicing is supported, with the laser scanner able to be replaced with just four screws, and no alignment necessary.

The RSL 200 also contains a removable configuration memory, making it easy to transfer the configuration to the new device.

With the RSL 200 app users can access status and diagnostic data in real time via Bluetooth directly from their smartphone or tablet (Android and iOS), even if access to the device is restricted. A digital service file can be forwarded directly to Leuze Service if required. The app enables uninterrupted diagnostics as the protective fields do not need to be disabled.

Leuze electronic Pty Ltd www.leuze.com.au

Robotic storage system transforms NZ pharmaceuticals warehouse

Douglas Pharmaceuticals, New Zealand’s largest privately owned pharmaceutical company and the country’s leading supplier by volume into the growing pharmacy channel, was outgrowing existing storage operations at its West Auckland warehouse for domestic orders to retail, wholesale and direct-to-consumer (DTC) customers, and needed to meet its bold growth targets.

Options explored included moving to a larger space off-site and increasing the footprint of the existing building. However, these came with drawbacks, including having to reconfigure the road network or move operations off Douglas’s campus in Henderson, Auckland. Douglas wanted a solution that didn’t just scale up its existing manual operation and associated challenges, but also futureproofed its warehouse operations by increasing density, efficiency, accuracy and throughput.

In the end, the company decided to approach Kardex to help expand its manual warehouse operations. As a result, New Zealand’s first AutoStore automated system is up and running at the Henderson site.

The AutoStore system comprises over 6000 storage bins and 13 robots, and has made picking four times faster. It also provides the extra inventory storage needed for Douglas to achieve its ambitious expansion goals without requiring the company to fund an expensive expansion of its current warehouse or move to a new location.

The AutoStore robotic cube storage system is transforming Douglas’s warehouse operations, after Kardex worked closely with Douglas to tailor the AutoStore solution to meet its current and future needs. Both companies describe the project as a true collaboration, praising the team for the success of the project, which came in on time and on budget.

Kardex says the AutoStore automated storage and retrieval system (ASRS) is the world’s fastest goods-to-person (GTP) system per square metre. It comprises bins stored in a high-density grid, with robots working to carry and deliver products to ports where they are picked and packed to customers’ orders.

Working with Kardex, Douglas reimagined its warehouse space to achieve 30% more storage using only 10% of the building’s footprint. The AutoStore system was installed following intensive planning and

modelling to ensure a smooth transition. It required no expensive physical changes to the warehouse or its power capacity, as 10 AutoStore robots consume as much energy as one vacuum cleaner. The primary adjustment was grinding the floor for the AutoStore Grid, and the system was built alongside Douglas’s existing warehousing operation to minimise disruption.

New ports and robots can easily be added in the future and the system is equipped with round-the-clock capabilities. It is expected to meet demand for the next five years in its current form. The AutoStore solution has increased picking rates by four times and delivers 99.9% accuracy. Robots handle product movement and Douglas employees pick items at ergonomic stations to reduce strain and enhance safety.

“I am so proud of the work done by our team and Kardex’s to meet and achieve our goals and ensure we are ready for an exciting future, expanding our consumer goods operation,” said Jeff Douglas, Managing Director of Douglas Pharmaceuticals. “This investment is futureproofing storage and fulfilment, reducing waste, and improving work for our warehouse team.”

“This is the future of fulfilment and we are impressed by the way in which Douglas and the whole team have embraced the technology and made it such a key part of their business,” added Grant Smith, Head of Business Development ANZ for Kardex.

Kardex www.kardex.com/en-au

NEWPRODUCTS

DEVELOPMENT ENVIRONMENT

Emerson has announced the release of PAC Machine Edition (PME) 10.6, an integrated development environment software used to configure and manage control system devices, including PACSystems PLCs and QuickPanel HMIs.

Emerson says the update offers a significant leap forward in capabilities, including simulation, data monitoring enhancements, optimised connectivity, and programming efficiency.

PACSystems Simulator is a newly incorporated component, empowering users to easily write, test and troubleshoot control logic on a PLC emulator. This can be done before purchasing new control hardware to speed development and ensure the correct selections are made.

A data monitor component helps to quickly diagnose and resolve logic issues using plotted data, whether the data is sourced from a physical PLC or the Simulator. With advanced configuration options for visualising and analysing data in a modernised display, and the ability to save and retrieve monitor configurations, users can gain insights into system dynamics, detect root causes of anomalies rapidly and uncover trending conditions.

A high-performance OPC-UA PAC Server accelerates PLC communication performance for visualisation and other client applications, with double the tag count capacity, faster start-up speeds, and improved processing efficiency. Similarly, Profinet enhancements provide more efficient configuration and operation for communication with intelligent field devices, such as I/O, sensors and variable frequency drives.

PME 10.6 also incorporates improvements for data handling. Enhanced User-Defined Types (UDTs) now propagate data element descriptions across all application instances, helping to ensure consistency while saving configuration time.

Emerson www.emerson.com/au/automation

In today’s fast-paced industrial landscape, automation, control, and instrumentation professionals play a critical role in driving efficiency, accuracy, and innovation within manufacturing and processing environments.

METTLER TOLEDO, a global leader in industrial weighing solutions, offers advanced technologies and products tailored to meet the unique challenges faced by these professionals. As the company prepares to showcase its expertise at ROKLive this July, it is timely to explore how METTLER TOLEDO’s weighing solutions and process analytics instruments empower automation, control, and instrumentation experts to enhance operational performance and ensure reliable, data-driven processes.

Automation and control systems rely heavily on precise measurement data to function correctly. METTLER TOLEDO’s industrial weighing and precision instruments provide unparalleled accuracy and repeatability that serve as the foundation for control loops, material handling, batching, and dosing systems. By integrating the company’s weighing modules, load cells, and analytical sensors, automation professionals can achieve exact measurements crucial for process consistency, product quality, and compliance with regulatory standards.

Instrumentation engineers value equipment that smoothly integrates into existing control systems and protocols. METTLER TOLEDO’s weighing solutions and analytical instruments support a broad range of communication interfaces such as ProfiBus, EtherNet/IP, Modbus and more, facilitating real-time data exchange with PLCs, SCADA systems, and DCS platforms. This connectivity ensures that weighing data can be easily monitored,

logged, and used for advanced process control and analytics, enhancing operational transparency and decision making.

Industrial environments often present challenging conditions such as exposure to dust, moisture, temperature fluctuations, and vibrations. METTLER TOLEDO designs its weighing and precision instruments with rugged construction and high ingress protection ratings to withstand these conditions. This durability guarantees consistent performance and reduces the risk of downtime or maintenance interruptions, which is vital for continuous automated operations.

Automation projects vary widely in scope and complexity. METTLER TOLEDO offers flexible solutions that can be customised and scaled to suit specific process requirements. Whether it is a standalone weighing station, multi-head filling system, or integrated process control, the products can be adapted to meet unique automation challenges. This scalability supports phased implementation strategies and future expansion.

Control and instrumentation professionals benefit from intuitive user interfaces and diagnostic tools embedded in METTLER TOLEDO’s solutions. Easy-to-navigate displays and configuration software reduce setup times and simplify maintenance routines. Built-in diagnostics help quickly identify issues, minimising downtime and enabling proactive maintenance, which is essential in automated production lines.

As industries evolve towards Industry 4.0, the integration of intelligent devices and data analytics becomes paramount. METTLER TOLEDO’s weighing solutions incorporate smart sensors and data management capabilities that align with

digital transformation initiatives. This enables automation professionals to harness predictive analytics, remote monitoring, and real-time process optimisation, driving greater efficiency and agility.

Looking ahead, METTLER TOLEDO is proud to announce its participation in ROKLIVE this July, a premier event for industrial automation and technology professionals. Visitors will have the opportunity to explore the latest innovations in industrial weighing technology, engage with METTLER TOLEDO experts, and discover customised solutions designed to meet the evolving needs of automation, control, and instrumentation fields.

METTLER TOLEDO’s industrial weighing solutions are more than just measurement tools; they are integral components that empower automation, control, and instrumentation professionals to optimise processes, ensure accuracy, and drive innovation. By offering precision, reliability, seamless integration, and smart capabilities, METTLER TOLEDO supports the advancement of industrial automation and the realisation of smarter manufacturing.

Experience firsthand how METTLER TOLEDO’s technologies can transform your automation and control projects into success stories. Connect with METTLER TOLEDO at ROKLive at the Gold Coast Convention Centre, 29–31 July at Stand 7.

Mettler-Toledo Ltd www.mt.com

INCREASING SENSOR LIFE IN HARSH CONDITIONS SENSOR SOLUTIONS FOR IMPACT,

HEAT AND SLAG RICH ENVIRONMENTS

Balluff Pty Ltd

Incorrect application of even the most advanced sensors can often lead to increased sensor wastage, higher production costs, and lower productivity.

Today’s new sensor designs are constantly improving. Advances in electronics, new sensor configurations, and increased sensor robustness are driving down the cost of sensors and increasing product quality and overall production efficiency. However, incorrect application of sensors — even of more advanced sensors — can often lead to increased sensor wastage, higher production costs, and lower productivity. In general, selecting a sensor that can do the job without the need for constant replacement, even if the sensor is of higher cost, is a far more efficient way to increase overall production productivity and profitability.

IT’S NOT JUST THE SENSOR

Think of a sensor as a mini system. There’s the sensor itself. Then there’s the means of holding it in position. Then there’s the connector and cable. And then there is the equipment and application expertise often needed to choose the right sensor for the job and to keep the sensor and its components from incurring premature failure.

Impact and abrasion, plus heat and slag are usually the conditions that are most dangerous to the sensor and to your overall productivity. Impact and abrasion can be found in almost any sensor environment. In addition, weld cells add to the added dangers of heat and slag.

IMPACT

Impact causes more sensor wastage than all other factors combined. In fact, the vast majority of all premature sensor failures are caused by systemic or incidental impact. If a sensor is in danger of being hit, there are five basic remedies to the situation:

• Use a more robust sensor

• Use a smaller sensor with the same range Use a different type of longer range sensor

• Move the sensor out of the way

• Protect the sensor

Use a more robust sensor

If the sensor is in danger of random impacts, using a one-piece stainless steel bodied sensor will greatly increase the life expectancy of the installation. These sensors will take repeated blows to their face and sides and still continue to function. Their housings are made from a gun drilled piece of solid 316 stainless steel or harder, creating an extremely rugged one piece body. These sensors can operate perfectly within the most physically abusive environments and continue to function — withstanding repeated blows from heavy objects during loading operations, or from general incidental impacts. Their ability to thrive in this difficult environment results in less downtime and lower maintenance costs. Some models are available in ferrous/nonferrous versions, extended range versions, plus extended range PTFE coated versions for weld cell applications.

Use a smaller sensor

Sometimes a sensor is just too big for the task and gets in the way of the action too easily. Today’s sensor technology is constantly reducing the ratio of size versus range. The remedy here is to switch to a smaller sensor with the same or greater range. Many inductive proximity models are available down to 3 mm in diameter.

Switch to a different kind of sensor

Another answer is to switch to a different sensor style, such as from an inductive proximity type to a long range photoelectric analog or digital sensor. Often, depending on the application, these types can do the same or better job as the inductive proximity sensor, but from a distance that keeps them out of harm’s way. Often this substitution will pay dividends in overall space utilisation. Replacing the existing sensor with a similar sized extended sensing range model works especially well where sensor face abrasion is the problem as opposed to direct impact. Another solution is to use a self-contained thru-beam fork sensor, which uses a laser beam to sense the position of a solid object. These sensors come in various configurations and sensing modes for use in a multitude of applications.

Move the sensor out of the impact zone

Sometimes this can be done by relocating the sensor slightly so that the trajectory of the object it is sensing will miss it automatically, or substituting one with greater range.

Use a device such as an inductive proximity actuato r

A prox actuator is a simple spring-loaded device that is inserted between an inductive sensor and its target such that the object being detected presses against the prox actuator, enabling the sensor to read the actuator instead of the primary object. This avoids damage to the sensor in systemic contact situations and can also be used in certain applications to protect the sensor from high heat.

Use a prox mount

Prox mounts offer additional protection from impact damage to a flush-style inductive proximity sensor by providing an external protection housing that encloses the entire sensor body up to the sensor face. Prox mounts also offer other productivity advantages such as the ability to provide fast removal and replacement of sensors without the need of physical readjustment.

Bunker your sensors

Bunkering sensors provide a higher degree of positive performance when it comes to resistance to severe impacts. Bunker blocks are cubes of solid aluminium or steel, designed to incorporate a prox mount within them. They come in different shapes to handle installations where space constraints occur.

Figure 1: Sensors can be destroyed by impact or abrasion. One-piece stainless steel sensors are therefore recommended for harsh sensing environments.

Extremely heavy impact may destroy a sensor, even when mounted in a prox mount, but a bunker block will resist unusually hard hits such as heavy parts being slung into a cell, or components inadvertently being dropped onto a weld cell. In addition, bunker blocks are constructed of heavy aluminium, which retards adherence of weld debris and also serves as thermal protection for the sensor.

HEAT AND SLAG

Heat, especially heat found in weld cells, is a major problem — not just for sensors, but for their associated cables and connectors as well. Hot slag accumulation and elevated ambient temperatures created by welding operations can degrade sensor performance and destroy unprotected connectivity. Weld cells can consume large quantities of sensors when they are not applied correctly, or are not protected from the hostile weld environment.

Use PTFE protection

Problems created by ambient heat and localised heat from weld splatter can be dramatically reduced by using protective products made with medical grade silicone, which provide total protection, not only for the sensor, but for the connector and cable as well.

Protecting sensors

Steel bodied sensors with PTFE coating are an unbeatable combination in weld cells where sensor weld field immunity is not required. However, weld fieldimmune (WFI) sensors equipped with a slag shedding PTFE coating on their faces are usually the sensors of choice in weld cell applications. When WFI sensors need further protection, bunker blocks equipped with quick-change prox mounts can be added. Since bunker blocks are made of machined aluminium and prox mounts are PTFE coated, the entire system repels weld slag accumulation while simultaneously acting as a heat sink.

Protect connectivity from heat and weld slag

It doesn’t help protecting the sensor only to have its connectivity fail. The first step to prevent connectivity failure in weld cells is to specify TPE jacketed cabling. TPE jackets withstand weld slag far better than PVC or PUR coatings. For added protection, specify PTFE products to finish the job and dramatically reduce weld cell maintenance. Medical grade silicone-based wrap and jacketing protects sensors, cabling and connectors not only from 500° ambient and localised slag heat, but from the accumulation of slag weight as well.

MPACT AND ABRASION, PLUS HEAT AND SLAG ARE USUALLY THE CONDITIONS THAT ARE MOST DANGEROUS TO THE SENSOR AND TO YOUR OVERALL PRODUCTIVITY.

Medical grade silicone jacketing slips over cabling, connectors and sensors to provide a heat barrier and prevent slag damage to the cable and connector. It is attached by silicone-based wrap, which is wrapped around the sensor and jacketing junction like tape around a hockey stick. This provides an entire assembly sealed from heat and slag, ready to last months rather than days. As an added benefit, since slag does not easily stick to the silicone jacketing, is that its weight doesn’t build up to pull cabling from its connectors. These products provide the most significant increase in weld cell productivity in years.

Figure 3: Protecting a sensor with a prox mount and a bunker block.

Figure 2: The face of this inductive proximity sensor is being worn away because it is too close to its target.

NEWPRODUCTS

ALL-IN-ONE CONTROLLER

Mitsubishi Electric has introduced the MELSEC MX controller, an all-in-one solution engineered for high-speed, high-precision applications. It combines sequence and motion control, while also integrating an OPC UA server and CC-Link IE TSN network to enhance data visibility and connectivity. Built-in cybersecurity features and enhanced no-code programming also help support digital transformation efforts.

The controller also meets the increasing demand for multi-axis control in fast-growing industries such as lithium-ion battery (LiB), semiconductor and LCD manufacturing, with high-speed control of 128 axes in 1.2 ms and multi-axis control for up to 256 axes.

The controller offers full CC-Link IE TSN compatibility across all models, enabling high-speed, synchronised communication. Combined with a software-based architecture running on a high-performance multi-core MPU, it is said to deliver up to 10 times the motion control performance of previous models.

To further boost productivity and reduce engineering workloads, the controller supports intuitive, one-tool development, AI-based debugging and analysis, and compliance with international programming standards. Variants tailored for motion control in food and packaging, EV manufacturing, and electronics production are also available.

Mitsubishi Electric is pursuing IEC62443-4-2 certification for cybersecurity.

Mitsubishi Electric Australia www.mitsubishielectric.com.au

COMPACT RADAR LEVEL TRANSMITTER

ETHERNET REMOTE I/O MODULES WITH MQTT

Metromatics has announced the local availability of Acromag’s BusWorks NT series Ethernet remote I/O modules that are designed to enhance IIoT capabilities with an integrated OPC UA server and MQTT client support to simplify data sharing and cloud connectivity across networks.

The BusWorks NT series Ethernet I/O modules are engineered for industrial environments requiring real-time monitoring and control, with applications spanning predictive maintenance, energy management, remote data acquisition and status monitoring. These modules ensure secure and standardised data exchanges, addressing the challenges of complex industrial communication systems.

Key features of the BusWorks NT Series include integrated IIoT protocols (OPC UA and MQTT) for secure, real-time data sharing between remote devices, cloud platforms and edge gateways, and dual protocol functionality, which combines IoT and industrial Ethernet protocols (Modbus TCP/IP, EtherNet/IP and Profinet) over a single network cable.

Each NTE Ethernet I/O model supports up to 16 I/O signals and can expand to 48 additional channels with NTX expansion modules, and supports various analog, discrete and temperature I/O configurations for voltage, current, relay and sensor inputs. They also feature a built-in web server for monitoring, control and easy configuration using a standard web browser.

The NT series modules also incorporate Acromag’s i2o peer-to-peer communication technology, enabling data transfers directly between modules without requiring a central host or master. For added flexibility, conditional logic with IF/THEN/ELSE statements allows users to customise operations efficiently.

Metromatics Pty Ltd www.metromatics.com.au

Hawk Measurement Systems (HAWK) has announced the launch of the Senator S60W, a compact radar level transmitter designed for continuous liquid level measurement across a wide range of industries.

The Senator S60W is said to offer a combination of high performance and chemical compatibility without sacrificing quality or ease of use. With a measuring range of up to 20 m, flexible mounting options and IP67 ingress protection, the S60W is engineered to perform reliably in demanding environments such as wet wells, sumps, tanks, river levels, pump stations and chemical storage facilities.

The S60W features Bluetooth commissioning through the HAWKBTConnect App, available on both Android and iOS platforms. Users can easily configure, monitor and troubleshoot the device remotely, streamlining operations and reducing setup time. Standard models come equipped with 4–20 mA output with HART and Modbus protocols.

For remote and isolated installations, HAWK also offers an ultra-low power Compact Modbus version of the S60W, supporting 5 VDC operation and scheduled measurement intervals — suitable for remote telemetry and battery-powered applications.

Hawk Measurement Systems Pty Ltd www.hawkmeasure.com

Navigating SIF logic solver selection

Why the Moore Industries SLA stands out

In industries where hazardous processes are part of daily operations, the importance of safety systems cannot be overstated.

Safety Instrumented Functions (SIF) are at the heart of these systems, designed to bring a process to a safe state when specific hazardous conditions arise. Each SIF is typically designed with its primary purpose to reduce risk, with its effectiveness quantified by its Safety Integrity Level (SIL) capability. SIL ranges span from SIL 1, offering basic risk reduction, up to SIL 4, which delivers the highest safety integrity and reliability.

Most SIFs are comprised of three key components: sensors to detect a hazardous condition, a logic solver to interpret the signal and make decisions, and final control elements to act on that decision. Among these, the logic solver is particularly critical — it is, quite literally, the brain of the system. Choosing the right logic solver is essential not only for compliance but for ensuring that when the moment comes, the SIF performs as designed and takes the hazardous condition to a safe state.

To meet the SIL requirements of any application, each device in the SIF must be properly evaluated. This evaluation focuses on whether the device has a proven track record or provides sufficient safety data — metrics like Safety Failure Fraction (SFF), Probability of Failure on Demand (PFDavg), and Systematic Capability (SC). These parameters are typically detailed in the manufacturer’s Failure Modes

Eff ects and Diagnostic Analysis (FMEDA) report or a formal safety certificate.

Logic solver selection generally falls into one of three categories. First is the proven in use approach, where the device's historical performance data demonstrates its suitability. Second is selecting a device supported by a manufacturer’s FMEDA report, which provides calculated failure data. Third — and increasingly viewed as the gold standard — is choosing a device that has been fully designed and manufactured in compliance with IEC 61508, complete with third-party certification and supporting safety documentation.

While proven-in-use data is an acceptable method to verify a device’s effectiveness, it often proves elusive in practice. Logic solvers, with their inherent complexity, rarely come with sufficient, verifiable historical performance data that satisfy stringent safety requirements. This leaves many safety professionals turning to manufacturer-provided failure data. While certainly easier to obtain, this data has its limitations. Most modern logic solvers fall into the ‘Type B’ category under IEC 61508, meaning they incorporate complex electronics and software. These systems can experience systematic failures — problems that arise not from predictable wear and tear, but from underlying design or firmware flaws. Unfortunately, failure data alone cannot fully capture these risks.

This is why the most reliable and futureproof path is to select a logic solver that is not

just well-documented but fully compliant with IEC 61508 and certified by an independent third party. Devices that meet this rigorous standard have undergone extensive scrutiny of both hardware and software development processes, addressing systematic faults through documented fault avoidance and control measures.

Enter the Moore Industries SLA logic solver. The SLA stands out because it ticks all the critical boxes for SIF logic solver selection. Designed from the ground up in full compliance with IEC 61508, the SLA is certified for SIL 3 applications by independent assessors. Its FMEDA report provides transparent, detailed safety data, enabling risk reduction calculations with confidence. But beyond meeting the standard, the SLA excels in usability. It avoids the unnecessary complexity often seen in safety PLCs, offering streamlined configuration menus for alarming, Excel-like maths and logic functions, and simple 2oo3 or even 5oo8 voting architecture safety schemes. In a world where safety integrity is paramount and compliance can be a labyrinth, the Moore Industries SLA provides a reassuringly straightforward answer. It combines rigorous safety design with practical simplicity, reducing the burden on safety practitioners while enhancing overall system reliability. For those tasked with ensuring that their safety systems are bulletproof when it matters most, the SLA is more than a logic solver: it is peace of mind.

Heat exchangers expand ginger beer production in Bundaberg

Established by the Fleming family in Bundaberg, Queensland, in 1968, Bundaberg Brewed Drinks has grown throughout its history as demand for its premium non-alcoholic, craft-brewed soft drinks has expanded. Evolving from a local supplier to an international brewed beverage manufacturer, the company’s iconic Bundaberg Ginger Beer has now become instantly recognisable on an international scale, with its distinctive glass stubby bottle and rip cap lid.

Continued increased demand in recent years meant that Bundaberg’s previous manufacturing facility was no longer large enough, and so it invested in a new greenfield project that would provide the company with the necessary space to accommodate future growth. Delivery of new production equipment was entrusted to longterm Bundaberg collaborator M.E. Engineering, an established process engineering company and systems integrator with particular experience in the food and beverage and distilling sectors.

The ginger beer brewing process includes several key stages, including grinding the dried ginger root, making the wort, fermenting with yeast, maturing and then mixing into the final recipe, before being filtered and bottled. Many of these stages require the ingredients or product to be heated or cooled, and HRS Heat Exchangers was chosen to provide the necessary heat exchangers to provide hot water, clean-in-place (CIP) solutions, and product heating and cooling throughout the brewery.

In particular, the HRS cooker and thermaliser are an integral part of Bundaberg’s Ginger Beer fermentation process, heating and cooling the wort as required. Both turnkey systems were supplied on process skids to facilitate installation and maintenance, and are based around the HRS MI and MR Series of corrugated tube heat exchangers.

The cooker system, which is designed to process up to 18.6 tonnes of product each hour, uses steam to raise the product temperature above 100°C. This is achieved in two stages, using an HRS MR Series heat exchanger with direct heat recovery reusing the heat removed when the product is cooled after cooking. A final cooling stage using an HRS MI Series heat exchanger lowers the product temperature further, to ambient conditions.

Thermalisation is a lower-temperature alternative to pasteurisation, and the thermaliser supplied at Bundaberg Brewed Drinks uses two types of heat exchanger in different processes to provide sufficient capacity to treat 25.5 tonnes of product every hour. The skid-mounted solution uses both MI and MR Series heat exchangers to raise the product to the required temperatures using both hot water and energy recovered from the subsequent cooling process. The cooling process, which also uses both MI and MR Series heat exchangers, returns the product to ambient temperature once thermalised.

“We were originally asked to quote solely for the supply of standalone heat exchangers; however, we quickly realised that an integrated

solution-based system mounted on a skid would provide Bundaberg with numerous efficiency benefits,” said Ella Taghavi, Sales Engineering Manager at HRS Heat Exchangers. “Key considerations for this project were the ability to provide the required thermal performance in an efficient package, in a solution which could be delivered within the required timescale and budget. Much of our ability to provide such a solution is down to our corrugated tube design which increases heat transfer efficiency while reducing the size of the necessary heat transfer surface, allowing us to provide compact and efficient systems.”

As is common with such projects, the final design was the result of significant consultation between all three parties involved in the project, and once designed the two systems were delivered in around 10 weeks. Commissioning was then carried out once the wider project overseen by M.E. Engineering was complete.

“One of our key considerations is ensuring the consistency of our product,” said Matt Brain, Project Manager at Bundaberg Brewed Drinks. “That means making sure the heating and cooling processes are reliably uniform, so that our ginger beer has the same familiar taste in every batch.

“One of the things we found when working with HRS was that they were able to extend the scope of their original brief in order to provide more options for us. Once the equipment was delivered, the installation and commissioning process went smoothly and since they have been operational, all the supplied heat exchangers have performed in excess of their design criteria, performing as intended.

“Working with HRS has been a seamless experience. Their equipment is of exceptional quality and the heat exchangers have all met our design criteria perfectly, ensuring our production runs smoothly and efficiently.”

HRS Heat Exchangers Pty Ltd www.hrs-heatexchangers.com/anz

Industrial networks and cybersecurity: are we keeping up with what we’re connecting?

Ella Averill-Russell, IICA Sydney Branch Manager

As Australia’s process industries become increasingly digitalised, the role of industrial networks is rapidly evolving. Once the realm of closed-loop, proprietary systems, today’s industrial environments demand open, scalable and secure connectivity — from plant floors to the cloud. Protocols like Profinet, OPC UA and Time-Sensitive Networking (TSN) are now key enablers in creating agile, interoperable networks — especially in sectors like water treatment, food manufacturing, energy and mining, where downtime is costly and visibility is critical.

The latest shift is the convergence of IT and OT systems — driven by the need for real-time insights and more intelligent control. Edge computing, paired with high-speed Ethernet protocols, allows for decentralised decision-making and predictive diagnostics at the device level. For example, Profinet over TSN enables time-critical automation traffic to coexist alongside non-deterministic data, ensuring safety, efficiency and flexibility without over-engineering the network.

Similarly, OPC UA is transforming cross-platform communication by embedding secure, vendor-neutral data models. It’s being used to connect not only PLCs and HMIs, but also enterprise-level systems — making it ideal for batch, utilities and multi-site production environments. These technologies are not just performance enhancers; they’re forming the backbone of digital transformation strategies.

However, with every new protocol, edge node or cloud interface added, the attack surface expands. Industrial control systems, traditionally isolated, are now connected to external networks. And while this brings operational benefits, it also introduces serious cyber risk.

Australia has already seen targeted attacks on critical infrastructure. In 2023, several local utilities experienced ransomware attempts that exploited unsecured remote access points. Most industrial networks still lack full visibility of connected assets, and many run legacy equipment with unpatched firmware, making them easy targets.

The IEC 62443 standard provides a structured approach to security, but compliance alone isn’t enough. What’s needed is a layered cybersecurity approach that includes:

• Network segmentation (zoning/conduits)

• Continuous monitoring and anomaly detection

• Role-based access controls

• Regular patching and firmware management

• Training to combat social engineering

Emerging tools like digital twins and passive network monitoring are helping asset owners understand vulnerabilities in real time, offering a much-needed shift from reactive to proactive cybersecurity.

Industrial networks are no longer passive highways — they’re active, intelligent systems critical to plant reliability and business continuity. The challenge isn’t just implementing Profinet or OPC UA; it’s doing so securely and strategically. For engineers and plant managers across Australia, the mission is clear: connect smarter, automate faster, and always design with resilience in mind.

June

Asia-Pacific International Conference on Additive Manufacturing (APICAM) 30 June – 2 July 2025

RMIT University, Melbourne www.apicam2025.com.au

July

Connecting Hydrogen APAC 2025 17–18 July 2025

Melbourne Convention and Exhibition Centre www.connectinghydrogenapac.com

Carbon Capture APAC 17–18 July 2025

Melbourne Convention and Exhibition Centre www.carboncaptureapac.com

CeMAT Australia 22–24 July 2025

The Dome, Sydney Olympic Park www.cemat.com.au

Industrial Transformation Australia 22–24 July 2025

The Dome, Sydney Olympic Park www.industrialtransformation.com.au

National Manufacturing Summit 2025 23–24 July 2025

Shangri-La Sydney manufacturingsummit.com.au

ReGen Circular Resource Expo 23–24 July 2025

ICC Sydney regenexpo.com.au

ROKLive Gold Coast 29–31 July 2025

Gold Coast Convention Centre www.rockwellautomation.com/en-au/events/roklivegoldcoast-2025.html

IICA Technology Expo Gladstone 30 July 2025

Gladstone Entertainment Convention Centre iica.org.au/Web/Web/Events/Event_Display. aspx?EventKey=IICAGLD25

August

2025 Center for Hydrogen Safety AsiaPacific Conference 12–14 August 2025

Sheraton Grand Sydney Hyde Park www.aiche.org/chs/conferences/center-hydrogen-safetyasia-pacific-conference/2025

IICA Technology Expo Sydney 13 August 2025

Smithfield RSL iica.org.au/Web/Web/Events/Event_Display. aspx?EventKey=IICASYD25

ENABLING OT EVOLUTION AND PROTOCOL

When the developers of Modbus began enabling communications from heterogeneous devices leveraging the RS-485 standard in 1979, it was off to the races for fieldbus communications interoperability.

RS-485 defines the electrical characteristics of drivers and receivers used in serial communications systems to connect a wide range of controllers, sensors, instrumentation, PID controllers, motor drives and more. DeviceNet, Profibus, SERCOS, ASi, Foundation Fieldbus and HART followed suit — all of which remain unencrypted.

OPC UA (IEC 62541), a unifying technology that bridges industrial automation and modern computing technologies, serves as the background for the interoperability spawned by vendors and suppliers, industrial and enterprise software and, yes, cloud service technologies. OPC UA standards allow

sensors to communicate with many types of controllers and devices to coordinate sensor data within a historian. This functionality allows enterprise layers to correlate process data with business functions without redundant software for translation. But how can all of this connectivity and data be networked and managed?

HUBS, SWITCHES AND MODERN NETWORKING

Before network switches, hubs were the main way to interconnect Ethernet-based networks. A hub is a quite simple device that physically copies each packet from its source port to each destination port and connects them to a single hub in a multicast manner.

While cheap and simple, this technology does not scale well because even a small network with a low number of clients has many packets transferring between

computers, causing too much traffic and potential packet collisions on the hub.

For example, if a client behind port 1 was exchanging packets with a client behind port 10, in principle, only these two ports should have seen those packets.

The solution for this predicament was the introduction of Ethernet switches. A switch is more sophisticated than a hub, as its hardware can better understand and route packets on a local network. It can read the Ethernet layer (the first 14 bytes, 6x2 for the MAC addresses and 2 for the EtherType, stating the protocol of the next layer; eg, IP), and some upper layers like ARP, and understand which MAC addresses are connected to each single port. With that, it builds what is called an ARP table and uses that to forward packets only to the right port(s), similar to the old switchboard used for telephone communications.

Broadcast packets, sent to all clients on a network, still require forwarding to all ports,

SPAN (SWITCHED PORT ANALYSER) PORTS, ALSO KNOWN AS MIRROR PORTS, WERE ORIGINALLY INTRODUCED BY CISCO TO ALLOW NETWORK ENGINEERS TO TROUBLESHOOT NETWORK ISSUES AROUND SWITCHES.

but the switch remains a huge improvement compared to the all-speak-to-all situation that is a reality with early hub technology.

Modern network switches have adopted increased capabilities to deal with complex network design complexities like VLANs and QoS and can even do router-like jobs if defined as ‘Layer 3 switches’, where packets are routed to their default MAC address gateways. Layer 3 switches support Virtual Router Redundancy Protocol (VRRP) and Open Shortest Path First (OSPF). VRRP provides automatic assignment. When a master router fails to connect, the backup router is automatically switched to the new master router. OSPF is often used in large

network-like substations; it can calculate the shortest route for data transmission and make the process more efficient.

All of the functions described above are designed to work at high speeds: originally at speeds of 10 Mbps, then 100 Mbps or 1000 Mbps. Today, certain switches can operate at tens of gigabits. To achieve that, an ASIC (application-specific integrated circuit) is usually employed. This hardware circuit is dedicated solely to the purposes of a switch, and while less flexible (it cannot be reprogrammed or used as a generic processing unit), it can transmit data at wire speed, where full gigabit traffic can be transmitted without packet loss and collision. Another CPU (central processing unit) remains to orchestrate other functions, configuration, set-up, etc.

SPAN PORTS ENTER THE CHAT

SPAN (switched port analyser) ports, also known as mirror ports, were originally introduced by Cisco to allow network engineers to troubleshoot network issues around switches. With hub technology, it was quite easy to understand what was going on in a network. All you needed to do was connect to a free port, and all packets flowing in that network were visible for inspection. But with switches, that is no longer possible.

A SPAN port is basically a configuration of one or more ports so that they can receive a copy of the traffic transferred on the switch, or in a specific VLAN, or on a set of ports. Nowadays, configurations are certainly more complex than in the beginning.

The beauty of SPAN port technology is that this capability is included in the ASIC unit discussed above; therefore, it does not affect network performance by eating into other tasks and services. For example, SPAN configurations will not cause the switch to drop packets on the other ports or introduce latency.

While there are no major concerns about performance when it comes to setting up SPAN ports, certain limitations can apply. Some older models may omit some packets to the SPAN port under certain situations, but the main and core functionalities of the switch won’t introduce delays in its wire speed.

ENABLING MONITORING FOR OT/ICS NETWORKS

In the early days of industrial cybersecurity network monitoring, an early milestone was

to produce a third-party certified review of SPAN port technology. The report confirmed that no impact on performance is observed when SPAN or mirror ports are used.

In that test, different kinds of switches of different brands and prices were tested to show that it was not essential to upgrade to the latest and greatest brand and model to enable network monitoring capabilities and introduce cybersecurity tools and controls.

Industrial control system (ICS) environments, largely comprising heterogeneous components with custom operating systems and network protocols, historically have had fewer cybersecurity tools designed to interrogate customised protocols and behaviours. This is especially true for areas of cyber-physical systems architecture closest to the field and I/O devices. Customised sensors, installed at a SPAN or TAP port within the customer network, passively monitor raw network data in real time without disrupting business operations, which provides real-time visibility into all network activity and the ability to alert on vulnerabilities, potential attacks in progress and emerging anomalies.

Modern networking, SPAN port evolution and protocol interoperability paved the way for operational technology (OT) and ICS network monitoring and cybersecurity. Today, security solution providers have expanded their software capabilities to interrogate the analysed traffic to include:

• complete database matching of known vulnerabilities and indicators of compromise;

• deep packet inspection to analyse packet traffic, commands and connectivity;

• threat intelligence feeds; and machine learning engines to define baseline network traffic and alert on anomalies in communications and process variables.

Such third-party security offerings offer holistic security awareness where vendor-specific options cannot cover heterogeneous systems across an environment. They enable continuous monitoring of multi-vendor OT systems and help secure otherwise insecure network traffic.

*Moreno Carullo is the technology expert behind Nozomi Networks’ cybersecurity solution for industrial control networks, and has a PhD in artificial intelligence and an extensive background in systems engineering and software development.

THE LAST WORD

AI-ENABLED

CONFIGURATION TRANSLATION

I grew up in a frustratingly monolingual household. This was in stark contrast to the primary and secondary schools I attended, both of which had large numbers of first-generation Italian, Greek and Asian students who had acquired sophisticated multilingual abilities.

As someone who is fluent in only one language and loves to travel, I am not surprised that language translation is one area where AI is having such a significant impact. The speed, accuracy and breadth of software-based language translation has greatly improved with the rapid adoption of AI-based software tools.

Automation has long been hampered by its own language translation problems. Configuration software prepared in one platform is not easily transferrable to another. Even systems from the same vendor, but of different generations, typically require complex translation. This problem has been recognised by many, including the Open Process Automation Forum, which defined configuration portability as a core objective. It is perfectly reasonable that end users, nominally operating the same plant in locations with different automation platforms, shouldn’t have to build and maintain unique configurations.

The accurate functional translation of configuration between automation systems is a complex and laborious task. This difficulty has long hindered automation modernisations. Because of the challenges imposed by the need to translate the configuration, end users have too often persevered with platforms — or vendors — that have long ceased providing the value expected from modern automation systems. The core of the translation challenge is that it requires a high level of proficiency in both the source and target systems. The software world is facing similar challenges, such as translating legacy COBOL codebase to modern alternatives.

Control system modernisation is typically a once-in-a-generation activity, rich with opportunity and risk. While the result of a system modernisation should provide a more maintainable, highly featured, expandable, easier-to-use system, there are significant risks. Among these are unplanned production losses, safety issues, equipment damage and operator disorientation.

Therefore, somewhat hardened by my career of modernising automation systems, I’m excited by the possibilities that AI can bring to this challenge. An example of such an initiative is Emerson’s DeltaV Revamp tool, where AI and ML power the assessment and translation of legacy system configuration into the DeltaV platform. If tools such as this can reduce the effort and risk of accurate functional translation, then the barriers to system modernisations can be greatly reduced. This will bring forward a whole host of benefits to end users.

In the same way that native languages of different cultures will always exist, it’s likely that different ‘languages’ of automation platforms will always exist. Perhaps the most efficient way of tackling this is through more effective translators. This will allow system vendors to differentiate and advance their platforms without the burden of potentially restrictive standards.

Some caution will of course be required. Errors in language translation between cultures might result in some embarrassment, but errors in automation configuration may have physical-world impacts. Some level of expert human translation will likely always be necessary to reach the standards required. Therefore, organisations that invest in both AI tools and their engineers will benefit most from the accuracy and speed of this new translation paradigm. As I see it, the coming years will offer great opportunities for the application of these exciting tools.

With over 25 years of experience delivering automation projects, Stephen Cowhey, Lead Engineer at Emerson, has a keen interest in the adoption of new technology to improve project execution.

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