Plant Engineering July August 2025

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Vol. 79 • No 4

Contents JULY/AUGUST 2025

14 | Equipment update guided by preventive or predictive ON THE COVER:

insights, ensures optimal performance and avoids costly downtime. Courtesy: ACS

AI

22 | Four ways to enhance APM and avoid downtime

p.18

Asset performance management (APM), a part of predictive maintenance, can help manufacturers proactively maximize equipment.

VIEWPOINT 7 | How big of an economic impact does your plant have?

About seven in 10 manufacturing firms have fewer than 20 employees. How large is their indirect impact?

INSIGHTS

10 | Experts share advice on hazards and hazard protection Experts offers advice on how to navigate common hazards in the manufacturing space.

SOLUTIONS 14 | Focus on renewed asset health, facility resilience with PdM Modern industries should move beyond reactive maintenance and adopt a strategic combination of preventive and predictive maintenance, alongside smart upgrades and long-term planning.

18 | Ways manufacturers can empower predictive maintenance with AI To keep up with industry, manufacturers need to innovate quickly. Industry trailblazers are implementing predictive maintenance techniques supercharged with AI.

26 | How to fulfill asset management with AI condition monitoring AI-powered analytics and automated condition monitoring are revolutionizing reliability.

29 | Look at manufacturing emission reductions to achieve sustainability

p.26

Plant and manufacturing engineers can pursue sustainability through innovative technologies.

32 | Off-the-shelf automation, material handling can save time, money Off-the-shelf material handling automation delivers full price transparency and same-day deployments while boosting throughput.

35 | How to determine the proper bulk material conveyance option

p.29

There are differences between pneumatic, aero-mechanical and flexible screw conveyance technologies for dry bulk material handling.

39 | A VFD user should know these induction motor calculations Understand more about alternating current motor specifications and calculations when using the motor with a variable frequency drive.

42 | Motor calculations made simple: optimizing performance

p.32

Motor selection starts with accurate calculations.

Properly sizing and specifying a motor is essential to building a reliable, energy-efficient drive system.

PLANT ENGINEERING ( Vol. 79, No. 4, ISSN 0032-082X, USPS PUBLICATION #790920 ) is published bimonthly by WTWH Media, LLC; 1111 Superior Ave., Suite 1120, Cleveland, OH 44114. Periodicals postage paid at Cleveland, OH and additional mailing offices. POSTMASTER: Send address changes to PLANT ENGINEERING, 1111 Superior Ave., Suite 1120, Cleveland, OH 44114. PLANT ENGINEERING copyright 2025 by WTWH Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of WTWH Media, LLC used under license. Circulation records are maintained at WTWH Media, LLC; 1111 Superior Ave., Suite 1120, Cleveland, OH 44114. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 Superior Ave., Suite 1120, Cleveland, OH 44114. Rates for non-qualified subscriptions, including all issues: USA, $120/yr; Canada/Mexico, $150/yr (includes 7% GST, GST#123397457); International air delivery $260/yr. Except for special issues where price changes are indicated, single copies are available for $30 US, $35 foreign. Please address all subscription mail to: PLANT ENGINEERING, 1111 Superior Ave., Suite 1120, Cleveland, OH 44114. Printed in the USA. WTWH Media, LLC, does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.

Plant engineering — www.plantengineering.com

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CONTENT

INSIGHTS

CONTENT SPECIALISTS/EDITORIAL

VIEWPOINT

AMARA ROZGUS, Editor-in-Chief ARozgus@WTWHMedia.com

SHERI KASPRZAK, Managing Editor SKasprzak@WTWHMedia.com MICHAEL SMITH, Art Director MSmith@WTWHMedia.com AMANDA PELLICCIONE, Marketing Research Manager APelliccione@WTWHMedia.com

EDITORIAL ADVISORY BOARD H. LANDIS “LANNY” FLOYD, IEEE Life Fellow JOHN GLENSKI, Principal, Automation & Digital Strategy, Plus Group, A Salas O'Brien Company MATTHEW GOSS, PE, PMP, CEM, CEA, CDSM, LEED AP, Senior Vice President, CDM Smith

CONTRIBUTORS WANTED Are you a subject matter expert in one of these topics? Would you like to write an article on one of the topics below? If so, please submit an idea to: www.plantengineering.com/contribute-to-plant-engineering • Compressed air systems • Expert Q&A: Plant automation • Expert Q&A: VFDs and VSDs • Lighting • Lubrication • Mechanical and electrical systems • Oils and lubrication • Preventive maintenance • Robots to improve efficiency • Rotating machine lubrication • Safety and PPE

WTWH Media Contributor Guidelines Overview Content For Engineers. WTWH Media focuses on engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends.

The link below gives an overview of how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers and other media. * Content should focus on helping engineers solve problems. Articles that are commercial in nature or that are critical of other products or organizations will be rejected.

(Technology discussions and comparative tables may be accepted if nonpromotional and if contributor corroborates information with sources cited.) * If the content meets criteria noted in guidelines, expect to see it first on the website. Content for enewsletters comes from content already available on the website.

All content for print also will be online. All content that appears in the print magazine will appear as space permits, and we will indicate in print if more content from that article is available online. * Deadlines for feature articles vary based on where it appears. Print-related content is due at least three months in advance of the publication date. Again, it is best to discuss all feature articles with the content manager prior to submission.

LEARN MORE AT: www.plantengineering.com/contributeto-plant-engineering

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PLE2508_MAG_INSIGHT_VIEWPOINT_V3msFINAL.indd 7

How big of an economic impact does your plant have?

About seven in 10 manufacturing firms have fewer than 20 employees. How large is their indirect impact?

A

Institute of Standards and Technology, recent article in the New for every dollar spent on manufacturYork Times lamented the ing, it creates $2.69 in total economloss of a paper mill, and ic activity. That might not sound like pointed out that for every a lot, but it multiplies when you start 100 jobs in durable manufacturing, adding zeros and commas. there are 744.1 indirect jobs lost.

While we talk about manThe Economic Policy Instiufacturing, supply chain tute released a report caland workforce development culating this information extensively at Plant Engineerin January 2019, which isn’t ing, we do not have the ability exactly new, but shows the to focus on all the other interripple affect across a region connected industries, such as or economy with manufactransportation, distribution turing job losses.

Amara Rozgus, or software development.

The report indicated that Editor-in-Chief We also do not have time to there are 16.5 indirect jobs focus on research and development lost per $1 million drop in demand (R&D), though the National Center for durable manufacturing, compared for Science and Engineering Statistics with 10.6 indirect jobs lost for the notes that manufacturing companies same drop in retail. The number of performed $326 billion — or 54% — jobs lost between the two industries of all domestic R&D in 2021. is close (18.3 in durable manufacturWhile Plant Engineering focuses ing and 20.5 in retail), so the initial on the practical elements of manufacjob loss numbers are more startling. turing, it's clear that the impact of this Most of these numbers are of high sector reaches far beyond the factory interest to economists, politicians and floor. Manufacturing is deeply interstatisticians. But they should interest twined with a wide array of industries everyone who touches manufacturing. and economic drivers — from supply There are backward linkages to conchains and workforce development to sider too, meaning that manufacturR&D and regional job creation. ing relies on a supply chain, perhaps Understanding the broader ripple raw metal or other components. There effects of manufacturing helps underare also forward linkages, meaning the score its role in economic resilience eventual output of a mill or producand national growth. For plant engition facilities. Linking the two together neers and manufacturing professioncreates employment multipliers, which als, recognizing these connections was reviewed carefully in the Economisn’t just informative — it’s essential to ic Policy Institute report. building a stronger, more sustainable There are also close links to the future for industry and the economy. PE economy. According to the National July/August 2025

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INSIGHTS

HAZARD PROTECTION AND HAZARDOUS ENVIRONMENTS

These experts share advice on hazards and hazard protection A panel of experts offers advice on how to navigate common hazards in the manufacturing space.

Question: What are some of the current hazard protection trends for industrial and manufacturing facilities?

Learning

Objectives

u

• Learn about the current trends in industrial hazards and hazard protection.

•U nderstand the role of design in helping organizations avoid hazards.

•D etermine the importance of standards and codes for ensuring a safe workforce.

Kyle Pollino: Current hazard protection trends for industrial and manufacturing facilities are increased awareness of fall protection, heightened awareness of rooftop safety and the use of crossover systems for greater safety around machinery and robotics.

Valéry Blanchet: Current trends in hazard protection for industrial and manufacturing facilities include proactive risk management and safety monitoring. Additionally, there's a focus on predictive maintenance tools to ensure the best level of protection anytime.

Herbert Post: Everyone's obsessed with predictive analytics now. I’ve heard of facilities installing internet of things (IoT) sensors everywhere with temperature monitors, vibration detectors, ergonomic sensors and gas sensors all feeding data to AI systems that supposedly predict failures before they happen.

Is it perfect? Nope. But it beats waiting for something to break.

Another trend that's impossible to ignore is wearable tech. Hard hats with built-in sensors, smart safety vests that track worker locations. I've even seen computer-generated and physical exoskeletons being

10 | July/August 2025 PLE2508_MAG_INSIGHTS_QA_V4msFINAL.indd 10

tested to reduce strain injuries. But getting workers to wear all this stuff remains a challenge, especially workers who feel like they’re being watched constantly.

There's also been a massive push toward inherently safer design. Basically, instead of adding more safety equipment, facilities are redesigning processes to eliminate hazards entirely, like switching to less toxic chemicals or lowering operating pressures. It makes sense when you think about it, as this uses the process of elimination and engineering to control hazards rather than depend on administrative controls or personal protective equipment (PPE).

Marc Elliott: At Eaton, we’re seeing hazard protection trends increasingly centered around proactive, data-driven maintenance practices and workforce training.

One major shift was the 2023 update to NFPA 70B: Standard for Electrical Equipment Maintenance, which now requires facilities to implement an electrical maintenance program (EMP).

This standard necessitates the ongoing evaluation of equipment condition to determine appropriate maintenance intervals. As with any EMP, the goal should be to establish an electrically safe working condition. That task can be simplified by using the operational data insights provided by digital technologies such as advanced sensors and software platforms that allow organizations to make smarter maintenance decisions based on continuous monitoring, refined data analytics and real-time diagnostics. These digital solutions can both simplify and improve traditional maintenance by providing the insights needed to properly maintain electrical equipment without personnel needing to physically occupy energized, hazardous environments.

Equally important is identifying the resources needed to help equip employees with the vast knowledge needed to maintain modern electrical systems.

When it comes to electrical safety education, there are more flexible options than ever before. For example, Eaton offers a comprehensive range of learning formats — including in-person, remote and on-demand — that help organizations build a skilled workforce capable of sustaining a culture of safety throughout the equipment life cycle. We even offer in-person training directly at our customer’s sites so personnel can learn hands on in their own environPlant engineering — www.plantengineering.com

7/28/25 9:53 AM

Participants

ment, with proper safety procedures implemented.

Ramon Farach: Rockwell Automation collaborates with many customers to design, implement and maintain safety instrumented systems (SIS). Historically, customers wanted to have dissimilar hardware and software for their SIS and their basic process control system (BPCS). This helped prevent an engineer or technician from accidentally working on the SIS when they meant to change the distributed control system (DCS). But it also requires extra training and staff who can work on both systems. Customers have taken an interest in keeping the BPCS and the DCS on the same hardware and software platform for ease of training, maintenance and use of common spares. They’re relying more on software-based safeguards like safety signatures and software locks to prevent mistakenly changing the wrong system.

Question: Looking ahead one to two years, what future trends should engineers, plant managers and designers expect for hazard protection?

John Binion: As one would expect, standards are getting stricter and less leniency is being granted when it comes to safety and environmental impacts that arise due to hazardous areas. As a process hazard analysis (PHA) facilitator, I am seeing more sites address hazards as if they are a given.

Marc Elliott: Looking ahead, engineers, plant managers and designers should prepare for a continued evolution of hazard protection best practices driven by the megatrends of electrification, decarbonization and increasing digitalization. As electrical systems grow in complexity, the evolution of EMPs must be seen as an ongoing journey.

For example, a key trend shaping the future of industrial environments is the rapid transformation of electrical systems. As facilities integrate renewable energy sources, electric vehicle (EV) fleet charging and the electrification of currently nonelectrical processes to support broader decarbonization efforts, the associated electrical loads and system configurations become much more complex. This introduces safety challenges and requires a new, deeper understanding of how to properly interact with and maintain these systems. It’s not just about understanding how these new components work, but about ensuring workers are trained to safely interact with them Plant engineering — www.plantengineering.com

PLE2508_MAG_INSIGHTS_QA_V4msFINAL.indd 11

John Binion

Process Safety Technical Consultant Hargrove Controls & Automation Mobile, Alabama

Ramon Farach

Global Chemical Industry Technical Consultant Rockwell Automation Nashville, Tennessee

Valéry Blanchet

Marc Elliott

Marketing Product Manager EMEA, Process Industries Emerson St. Louis

Director of Mining, Metals, Minerals, Pulp and Paper Eaton Pittsburgh

Kyle Pollino

Herbert Post

Safety Consultant OSCO Safety Belle, West Virginia

and that protection systems are designed and sized correctly to safely manage evolving energy demands.

Regulatory changes are also on the horizon. Committees for NFPA 70: National Electrical Code and NFPA 70B are preparing updates for the 2026 code cycle with expected changes reflecting current industrial electrical system trends. These include expanded guidance on higher voltage systems, updated arc flash labeling requirements, accommodations for EV charging infrastructure and refined working space standards. For NFPA 70B specifically, revised language is anticipated that reinforces the use of digital monitoring solutions to determine maintenance intervals, further reinforcing the shift toward predictive, condition-based strategies.

Even if the latest codes aren't immediately adopted in every jurisdiction, it's vital to recognize that relying on outdated standards can result in missed opportunities for safety improvements and modern best practices. By staying ahead of upcoming changes and designing with the latest standards in mind, facilities can elevate their safety posture well beyond

Vice President, Safety and Health TRADESAFE Las Vegas

‘

At Eaton, we’re

seeing hazard

protection trends increasingly centered around proactive, datadriven maintenance practices and workforce training.

— Marc Elliott, Eaton

July/August 2025

’

| 11 7/29/25 1:44 PM

INSIGHTS

HAZARD PROTECTION AND HAZARDOUS ENVIRONMENTS

FIGURE 1 : OSCO Safety recently installed its ReadySeries modular stair tower system for a client that needed access to two elevated tanks to perform routine maintenance. Courtesy: OSCO Safety

Insights

u

Safety hazards insights u Getting ahead of hazards

through predictive and preventive maintenance is a current trend.

u It’s imperative for

organizations to continue training in hazard prevention ­— even after they’ve adopted a plan.

u Technology, including

software, augmented reality and virtual reality, are changing the ways in which workers engage in safety training.

the baseline, enhancing both personnel protection and operational reliability.

Herbert Post: The big standard coming could include the Occupational Safety and Health Administration’s (OSHA) heat illness prevention standard.

There are a lot of practical ways to monitor worker safety, as we are already seeing facilities install cooling stations, but the acclimatization tracking is tricky. How do you document someone's heat exposure over two weeks?

Some facilities run contests or standardize the workers’ water consumption, whereby they track the amount of water/hydration product they drink, which helps workers become more aware of their own hydration. There are also products that base their hydration formulas on scientific studies involving sweat and salt consumption. Hazard control also includes work/rest regimens for specific PPE. Tools like the heat index and the wet-bulb globe temperature are still widely used to manage heat exposure and reduce injuries.

Artificial intelligence (AI) predictive maintenance is finally becoming practical. Insurance companies are starting to offer discounts for facilities using IoT sensors. System costs depend on monitoring. A basic vibration setup for critical pumps can be cheaper than full plant coverage. Most vendors claim to see a 12- to 18-month payback through prevented failures.

Wearables also keep getting pushed by vendors.

These show significant reductions in overexposure incidents by tracking cumulative exposure to hazards like silica, noise and chemical vapors. These devices are getting more sophisticated. Some now sync with facility management systems to create heat maps of exposure zones.

Connected worker platforms are also interesting. Real-time location tracking, man-down alerts and emergency mustering turn workers into walking data points. Privacy concerns aside, these are becoming standard for remote, confined-space monitoring and high-risk areas. Some integrate with access control wherein gates won't open if you don't have the right training certificate on file.

Kyle Pollino: Looking ahead one to two years, the future trends managers should expect in hazard protection are tools to safeguard workers from rapidly evolving technology, such as automated equipment and robotics.

These technological advances can improve performance and throughput, but safety measures

12 | July/August 2025 PLE2508_MAG_INSIGHTS_QA_V4msFINAL.indd 12

‘

To excel in hazard protection duties, it is important to understand your role

and responsibilities. Then, identify all potential hazards and learn to assess and control risks.

’

—Valery Blacnhet, Emerson

such as lane control and protective guarding will be important as humans and machines learn to work together in the industrial world.

Ramon Farach: The use of AI will become more prevalent in plants, first around process optimization and asset management, but it will extend to advanced detection of process hazards and alerting operators to take corrective action sooner. This requires a robust, modern operational technology (OT) foundation that can be connected to the information technology (IT) system required to analyze data and provide operator feedback. However, most chemical manufacturers are just starting to consider modernization and digitalization of their plants. It’s time for facilities to assess automation and control systems and begin their modernization and digitalization journey.

Question: Describe a project in which you had to design or modify systems to protect from a hazardous environment. What were the challenges and solutions?

Valéry Blanchet: A rubber manufacturer needed to replace a 40-year-old tank system. Emerson delivered an industry compliant solution with higher peak pressure capability and advanced piloting and monitoring controls to ensure longer service life, lower emissions and streamlined operation.

It is a typical example where efficiency, productivity and safety has been improved with a better control and technical improvements.

Kyle Pollino: A recent project involved a client that needed access to two elevated tanks to perform routine maintenance on the tanks. The challenges included working around preexisting structures and addressing areas of heavy pedestrian traffic. We were able to install the ReadySeries modular stair tower system, which shipped fully assembled for the least amount of downtime. We also provided a full Professional Engineer-stamped engineering package to ensure the structural integrity of the system. PE Plant engineering — www.plantengineering.com

7/28/25 9:53 AM

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ENGINEERING SOLUTIONS PREDICTIVE AND PREVENTIVE MAINTENANCE Andrew Harris, ACS, Verona, Wisconsin

Focus on renewed asset health, facility resilience with PdM Modern industries should move beyond reactive maintenance and adopt a strategic combination of preventive and predictive maintenance, alongside smart upgrades and long-term planning.

I Learning

Objectives

u

• Understand the limitations of reactive "break-fix" maintenance and recognize its negative impacts on operational efficiency, costs and safety in industrial settings.

• Identify and differentiate between preventive and predictive maintenance strategies and grasp the benefits of integrating both approaches for optimal asset management and facility resilience.

• Recognize the strategic role of technology, including AI, machine learning and digital twins, in enabling proactive maintenance, smart upgrades and longterm infrastructure planning for sustained operational success.

n industrial environments, companies invest significant capital in equipment and infrastructure, often ranging from tens of thousands to several million dollars. Maximizing the longevity and performance of these assets is not just a matter of protecting investments; it’s essential for operational efficiency and competitiveness. With the right maintenance strategies, systems installed decades ago can continue to function effectively today.

Achieving such durability, however, means abandoning outdated, reactive maintenance models.

The “break-fix” approach — waiting for equipment to fail before acting — is still common, especially when resources are stretched thin. This philosophy is increasingly unsustainable. It leads to unplanned downtime, costly emergency repairs and elevated safety risks, particularly in environments where precise testing or continuous operation is critical.

The urgency to modernize maintenance practices is further amplified by the rapid pace of technological change. Equipment can become obsolete long before it physically fails. Since 2020, for example, the growth of electric vehicle research and development has dramatically shortened the typical technology cycle, requiring systems and processes to adapt more quickly than ever. Facilities that take a passive stance risk falling behind.

14 | July/August 2025 PLE2508_MAG_PDM_ACS_V3msFINAL.indd 14

To address these challenges, forward-looking organizations are embracing a more integrated, strategic approach — combining preventive and predictive maintenance (PdM) with smart upgrades and long-term infrastructure planning. This approach blends engineering discipline, operational strategy and future-ready technology into a cohesive asset management philosophy.

Preventive and predictive maintenance Preventive maintenance (PM) remains the cornerstone of reliable operations. It involves systematically inspecting, cleaning, calibrating and replacing parts at regular intervals or based on usage metrics.

While these tasks may seem routine, they are essential to avoiding unexpected failures and preserving equipment reliability.

Neglecting PM has well-documented consequences: increased downtime, higher repair costs and compromised safety. In contrast, facilities that adhere to well-structured PM programs enjoy more consistent performance, longer asset life and improved operational control. Studies have shown that effective PM can reduce overall maintenance costs by 12% to 18% compared to reactive strategies.

Still, PM alone is not enough in an era of complex, interconnected systems. That’s where PdM comes into play. Unlike PM, which follows a schedule, PdM is condition-based. It relies on real-time data from sensors and digital systems to forecast failures before they occur.

Implementing PdM requires a technological foundation — sensors to collect performance data, software to interpret that data and algorithms to detect anomalies or predict breakdowns. These systems can flag early signs of wear or inefficiency, allowing maintenance teams to intervene when repairs are most cost-effective and least disruptive.

The benefits are clear: fewer breakdowns, reduced maintenance costs and longer operational lifespans.

Plant engineering — www.plantengineering.com

7/28/25 9:54 AM

‘

The most effective organizations

don’t wait for failures to force change

’

— they plan upgrades.

How PdM is better than deferred maintenance The risks of reactive maintenance extend beyond equipment failure. Facilities themselves age and when their structural integrity is compromised, the effects ripple across operations. Roof leaks, worn flooring, failing heating, ventilation and air conditioning (HVAC) systems and outdated power infrastructure may seem like background issues, but they can jeopardize both safety and productivity.

In high-performance test environments, even minor infrastructure problems can halt operations or damage sensitive equipment. Water intrusion, for instance, can short-circuit electrical systems.

Dust and debris from crumbling ceilings or corroded ducts can contaminate controlled environments.

Unfortunately, many facilities rely on short-term fixes instead of investing in long-term upgrades, often because those upgrades weren’t included in the initial project scope.

Over time, deferred maintenance accumulates into significant liabilities, frequently demanding emergency capital outlays or complete system overhauls. Avoiding this outcome requires proactive infrastructure planning and embedding capital improvement strategies into the earliest phases of project development.

A holistic approach to planning A robust maintenance strategy starts with strategic planning. At the outset of any major initiative, organizations must clearly define their objectives, align stakeholders and set performance and life cycle targets for both equipment and facilities. This alignment helps avoid short-term thinking and lays the foundation for adaptability as needs evolve.

Cross-functional collaboration is also key.

Effective strategies require input from engineers, information technology professionals, operations teams and facility managers alike. Each group brings vital knowledge to the table, helping ensure that upgrades are both technically sound and operationally practical.

Plant engineering — www.plantengineering.com

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Furthermore, long-term success depends on designing facilities with flexibility in mind. That means planning infrastructure to accommodate future expansion, allocating budget for ongoing upgrades and coordinating among projects to avoid redundant systems. Instead of relying on temporary solutions, organizations benefit from phased upgrades and shared infrastructure that support evolving operational needs.

Allocating a small, consistent percentage of each project’s budget toward facility improvements helps ensure that infrastructure keeps pace with equipment demands. It also mitigates the temptation to cut corners when margins are tight, preserving long-term resilience.

FIGURE 1: Equipment update guided by preventive or predictive insights, ensures optimal performance and avoids costly downtime.

Courtesy: ACS

How looking ahead can improve maintenance Eventually, every system requires an upgrade.

The most effective organizations don’t wait for failures to force change — they plan upgrades as part of a continuous asset life cycle. This process involves balancing technical rigor with practical innovation.

Data and analytics play a critical role. Performance metrics and predictive models help identify July/August 2025

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ENGINEERING SOLUTIONS PREDICTIVE AND PREVENTIVE MAINTENANCE

FIGURE 3: Machine learning and digital twins are revolutionizing industrial maintenance for enhanced reliability. Courtesy: ACS

FIGURE 2: This futureproofed test cell incorporates predictive maintenance and smart upgrades, ensuring long-term resilience and keeping us ahead of the curve in testing capabilities.

Courtesy: ACS

Insights

u

Predictive maintenance (PdM) insights u Predictive maintenance

is rapidly replacing outdated reactive models, allowing industrial facilities to anticipate failures, reduce downtime and extend equipment life through real-time data and advanced analytics.

u By integrating PdM with

preventive strategies and smart infrastructure planning, forwardthinking organizations are transforming maintenance from a cost center into a driver of resilience, efficiency and long-term growth.

system weaknesses and guide upgrade priorities. At the same time, creative engineering enables facilities to incorporate new capabilities within existing footprints, leveraging modular designs, standardized interfaces and flexible configurations.

Rather than viewing upgrades as isolated capital events, forward-looking facilities treat them as integral components of their long-term growth strategies.

Making PdM smarter with technology Emerging technologies are redefining what's possible in maintenance and facility operations.

Artificial intelligence and machine learning enable advanced predictive analytics, detecting failures before symptoms even emerge. These systems continuously refine themselves, creating a self-improving feedback loop.

Software-defined automation is also gaining traction, moving control functions from traditional hardware into the cloud or edge platforms.

This shift allows for faster reconfiguration, remote updates and more adaptive system performance — all of which are essential for PdM and real-time monitoring.

Meanwhile, digital twins are providing new levels of insight into system performance. By creating a real-time virtual model of physical systems,

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digital twins allow engineers to simulate scenarios, assess efficiency improvements and guide maintenance decisions with greater precision.

When paired with smart infrastructure — self-regulating HVAC, intelligent lighting and responsive utility systems — these technologies create intelligent, adaptive facilities capable of anticipating and responding to operational demands.

PdM is becoming a strategic imperative The age of reactive maintenance is over. In its place is a strategic model that prioritizes resilience, efficiency and future readiness. PM and PdM, combined with smart upgrades and long-range planning, enable organizations to extract maximum value from their assets while avoiding costly disruptions.

To thrive in the competitive landscape, manufacturing facilities must adopt a proactive mindset: setting clear goals, investing in technology, collaborating across disciplines and embedding maintenance into the core of operational planning.

Maintenance is no longer just about preventing breakdowns. It’s about building intelligent, futureready operations that drive performance, support innovation and ensure long-term sustainability in an ever-evolving industrial world. PE Andrew Harris is Controls Engineering Team Lead - Michigan | Director of Business Development – Controls at ACS. ACS is a certified member of the Control System Integrators Association (CSIA).

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ENGINEERING SOLUTIONS PREDICTIVE AND PREVENTIVE MAINTENANCE Kendra DeKeyrel, IBM Automation Software, Austin, Texas

Ways manufacturers can empower predictive maintenance with AI To keep up with industry, manufacturers need to innovate quickly. Industry trailblazers are implementing predictive maintenance techniques supercharged with artificial intelligence (AI) for more efficient operations.

F

or asset-intensive industries such as manufacturing, organizations are always seeking new ways to improve their operations.

Often, manufacturers have long-established processes to maintain their assets such as deploying condition-based maintenance techniques to keep their conveyor belts and assembling machinery running. For many, these systems have yielded

AI FIGURE 1: Manufacturers that integrate predictive maintenance techniques supercharged with artificial intelligence can get a full view of the state of their assets and a anticipate failures. This look-ahead approach to maintenance will help drive maximum efficiency. Courtesy: IBM Blue Studio

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positive results for decades so they may be hesitant to change them and want to avoid any unnecessary disruptions.

Manufacturers who want to stay ahead of the pack will invest in ways to seamlessly incorporate innovation into these systems. Asset life cycle management (ALM) techniques powered by artificial intelligence (AI) are crucial to optimizing their asset maintenance and enhancing results.

To take it one step further, those shifting from preventive to predictive maintenance — with the help of AI-powered technology — are already seeing more efficient, sustainable and resilient operations.

Traditionally, organizations relied on reactive maintenance, waiting for a machine to break down or preventive maintenance, inspecting assets at a set time each month. These approaches can waste resources, time or both.

Predictive maintenance, however, is the process of using historical data, analytics and internet of things (IoT) to anticipate when assets would fail and plan maintenance activities accordingly. In simple terms, this approach is all about collecting the right information and sharing it at the right time to empower the right people to act.

This approach helps head off defects and failures before they occur, avoiding unplanned asset downtime and helping to achieve further operational efficiency.

One IBM client, Spendrups Bryggeri, is leveraging technology that helps the brewery deploy predictive maintenance techniques to enhance its sprawling maintenance operations. This Swedish brewing giant wanted to create a new set of best practices while being mindful of its pre-exiting working methodologies. By introducing technolPlant engineering — www.plantengineering.com

7/28/25 9:56 AM

‘

Businesses who can effectively capture, understand and harness the data from their assets will excel at ALM and see the best results when implementing predictive maintenance

’

and outcompeting those who don't.

ogy such as mobile features that showcase critical asset information on the go while heavily engaging its staff, the company were able to seamlessly incorporate AI-powered solutions into its dayto-day work. Thanks to AI-powered software, Spendrups Bryggeri collects equipment data, proactively identifying issues and empowering the team with the information they need to maintain production equipment in peak condition and extend the machine’s life spans.

Predictive maintenance as the heart of ALM Predictive maintenance is part of a broader approach to manufacturing called ALM. ALM entails the careful monitoring of assets such as machinery, warehouses or fleets of vehicles across their full life span — from their very first usage to their last day on the job.

Tools like IoT sensors are used to monitor assets at scale and in detail, collecting real-time insights that build into a rich, historical data set on that specific asset. That data helps companies engage in predictive maintenance.

For example, sensors and cameras can be installed to monitor an assembly robot and its performance data can be displayed via specific dashboards. An organization may choose to invest in AI-powered technology that can analyze this historical data and pinpoint when the robot will need to be serviced or an arm be changed and why.

Then, employees can plan this maintenance work accordingly and ensure the necessary equipment backups are available to avoid downtime as much as possible.

Businesses who can effectively capture, understand and harness the data from their assets will excel at ALM and see the best results when implementing predictive maintenance and outcompeting those who don't.

Plant engineering — www.plantengineering.com

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FIGURE 2: A screen captures IBM Maximo Manage, Mobile and Scheduler, which were leveraged by Swedish brewery Spendrups Bryggeri to deploy predictive maintenance techniques. Courtesy: IBM

FIGURE 3: Leveraging artificial intelligence-powered technology can, in practice, be as simple as providing a technician with easy to decipher data on a computer dashboard. This coupled with real-time updates and human expertise can lead to smarter

Asset data can become overwhelming without the proper tools to collect and analyze it. To mitigate this, organizations should invest in technology that can collect, compile and analyze data for easier analysis. This type of software can then use analytics and AI — including generative AI — to transform this data into predictive intelligence, automated workflows and help with strategic decision making.

How AI will change the manufacturing industry AI-powered tools are becoming the new normal and are enhancing the way manufacturers work.

Because the insights provided by AI can predict future asset disruptions and recommend maintenance accordingly, employees will need to adapt to this new way of working. There will be less need for manual inspections or data entry. Instead, generative AI can enable features like notifying technicians that a specific asset should be serviced and

maintenance processes.

Courtesy: IBM Blue Studio

Learning

Objectives

u

• Discover how artificial intelligence (AI) is changing the ways in which manufacturers approach maintenance.

• Learn how embedded AI technologies can complement skilled workers.

• Determine the ways in which historical data contribute to predictive maintenance.

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ENGINEERING SOLUTIONS PREDICTIVE AND PREVENTIVE MAINTENANCE

Insights

u

u Shifting maintenance

efforts from preventive to predictive has become a business imperative for success in asset intensive industries.

u Manufacturers need

to adopt cutting-edge technology that easily integrates with traditional processes, Asset lifecycle management (ALM) will be key for this era of seamless innovation.

u As agentic AI becomes

more prevalent, organizations should seek this tool to complement human expertise and drive efficiency.

why according to historical data. Only then would the technician go to inspect that specific machinery and make the necessary adjustments for optimal performance.

Many are concerned that more advanced AI technology, such as AI agents, may replace human expertise. However, AI acts as a supplement for tasks, freeing up employees from repetitive manual tasks so their time can be better spent. For example, an AI agent can comb through historical data and alert a technician to predict that a specific asset will to malfunction and when, open a work order and provide a suggestion as to the cause for the issue.

The employee will still need to inspect the asset, verify the malfunction and approve the suggested cause. However, this process is simplified thanks to readily accessible historical data displayed in an easy-to-read dashboard.

Another example of how AI agents can complement human expertise is by empowering technicians with specific maintenance information. AI agent technology can be trained with troubleshoot-

ing information specific to the make and model of the assets in a factory and bring these up upon detecting a specific type of failure. An expert will then need to be deployed to conduct the repairs, and the agent can even walk them through the recommended steps to follow if needed.

How manufacturers will use embedded AI for maintenance While manufacturers continue to face an ever-changing landscape, they should continue to seek different ways to stay nimble. New innovations such as chatbots that help understand an asset’s performance or agents that can kickstart an inspection with the press of a button are emerging are coming. Manufacturers that invest in successfully embedding AI into daily operations will stay ahead of the pack. PE Kendra DeKeyrel is the Vice President Asset Life Cycle Management Product and Engineering Leader for IBM Automation Software.

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ENGINEERING SOLUTIONS PREDICTIVE AND PREVENTIVE MAINTENANCE Nelson Squires, Wesco, Pittsburgh

Four ways to enhance APM and avoid downtime Asset performance management (APM), a part of predictive maintenance, can help manufacturers proactively maximize equipment, minimize unplanned downtime, provide greater visibility into operations and leverage real-time data to keep operations running smoothly.

D

ata has become the lifeblood of many critical manufacturing processes, providing the insight and actionable details needed to keep operations running efficiently.

This is especially critical when it comes to improving the performance of equipment throughout its life cycle. Properly using machine data can

enable a proactive and predictive approach to maintenance that can help address concerns before they take production offline.

Asset performance management (APM) has emerged as a critical component of this effort. The ability to track everything from vibration analysis to machine efficiency, equipment health to production schedule data and then leverage that information to make real-time decisions, can mean the difference between smooth production and significant operational losses due to machine failure.

This is no small matter. Unplanned downtime costs industrial manufacturers an estimated $50 billion annually, according to industry statistics.

With greater visibility into operations and the ability to minimize costly, unplanned downtime, APM solutions can help manufacturers make smarter decisions around machine performance, efficiency and even labor management. As the manufacturing industry continues to contend with a skilled labor shortage, APM can also bridge that gap by directing resources to the most pressing maintenance concerns and preventing problems before they start.

Approaching maintenance with APM Let’s take a look at the four ways APM solutions can provide a comprehensive view of asset management and help enable a proactive, predictive approach to maintenance:

1. Better navigate and manage labor challenges

The workforce is shrinking. As experienced employees with plant floor expertise retire, bringFIGURE 1: Properly using machine data can enable a proactive and predictive approach to maintenance that can help address concerns before they take production offline. Courtesy: Wesco

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Plant engineering — www.plantengineering.com

7/28/25 9:58 AM

Learning

Objectives

u

•D iscover how asset performance management (APM) helps bridge the gap of workforce shortages and maximize equipment throughput.

•L earn how proactive maintenance can reduce equipment breakdown and avoid unplanned downtime •U nderstand how an asset planning solution gives manufacturers the ability to harness real-time data from equipment and transform it into actionable insights

ing new workers up to speed remains a significant challenge. To help overcome this, APM can help manufacturers navigate the impact that labor shortages or less-experienced teams can have on maintenance programs. By leveraging historical processes, consistent data feeds, intuitive dashboards and automated alerts, APM can help ensure that onboarding newer workers is quicker and smoother and that the knowledge base of more experienced workers isn’t lost in the process.

Providing detailed insights into machine performance helps less experienced workers understand when they need to take action and helps streamline overall maintenance efforts. This also allows less experienced operators to perform more consistent, automated monitoring and decision making.

APM can also leverage historical data for insights into machine performance. This unique ability to look behind and plan, ensures maintenance requirements can be addressed more effectively and efficiently.

2. Avoid equipment breakdowns

When a machine breaks down, it isn’t just an inconvenience, it can cause a costly chain reaction: missed delivery deadlines, lost productivity and unsatisfied customers. Given the shrinking pool of skilled labor, manually inspecting machines outside of standard maintenance schedules is not always feasible.

APM solutions allow manufacturers to proactively monitor equipment health and receive alerts when a machine begins showing signs of wear or malfunction or if they’re operating below optimal capacity. Tools such as data visualization, analytics and alerts work together to consistently monitor the performance and health of machines in real-time. This enables businesses to stay ahead of potential equipment failures and mitigate concerns before they become problems that impact overall

Plant engineering — www.plantengineering.com

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FIGURE 2: Asset performance management solutions allow manufacturers to proactively monitor equipment health and receive alerts when a machine begins showing signs of wear or malfunction, or if they're operating below optimal capacity. Courtesy: Wesco

production efficiency or lead to costly, unplanned downtime.

It's important to note that with APM, automated alerts can also be monitored remotely. This reduces the need and expense for onsite expertise and enables businesses to leverage expertise across locations.

3. Overall equipment effectiveness (OEE) as part of a proactive maintenance effort OEE is a critical component of any predictive maintenance effort. Without those metrics, it’s difficult to measure how operations are running and if or how it could be improved. Getting ahead of scheduled maintenance and using condition-based maintenance, which uses real-time data to predict when a machine will need service, helps manufacturers address issues before they lead to major disruptions. This, in turn, extends the life of equipment and avoids costly repairs or replacements. APM solutions can help manufacturers embrace a proactive approach to maintenance, enabling machines to stay up and running as much as possible.

‘

Unplanned

downtime costs industrial manufacturers an estimated $50 billion annually, according to industry

’

statistics.

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ENGINEERING SOLUTIONS PREDICTIVE AND PREVENTIVE MAINTENANCE

Insights

u

Asset performance management (APM) insights u APM can make

For example, if a particular machine is operating below its optimal capacity, an APM alert allows workflows to be adjusted or resources to be reallocated to maintain efficiency. This level of visibility helps maximize throughput and enhances OEE, ensuring that production lines are running at peak performance and operational requirements are being met.

onboarding newer employers easier by leveraging historical processes, consistent data feeds, intuitive dashboards and automated alerts.

4. Transform equipment data into actionable insights One of the greatest advantages of APM solutions is that they help manufacturers stay agile and responsive, transforming real-time equipment u Plants can adjust data into actionable insights that drive decisions. productionschedulesbased For instance, it could help adjust production on real-time performance data, ensuring lines operate schedules based on real-time performance data, at peak efficiency. ensuring that lines are operating at peak efficienu Manufacturers can cy — or not running if they’re not needed. By proactively monitor leveraging historical data, it could predict when a equipment health and receive alerts when machine will likely need maintenance and identify a machine begins a timeframe to service the equipment — perhaps showing signs of wear of July 11 Half Page Ad_V2.pdf 2 7/14/2025 8:40:57 AM a less critical period — effectively miniduring malfunction.

mizing production impacts. By presenting aggregate data in an easy-to-understand dashboard, APM solutions provide manufacturers with the ability to make sense of the data their machines are generating.

In the competitive and evolving manufacturing environment, it’s more important than ever that organizations use every tool at their disposal — in this case the power of data, real-time insights and predictive maintenance — to stay ahead of equipment failures, maximize throughput and overcome workforce challenges.

Building an agile, resilient operation starts with informed decisions. By relying on powerful data insights from APM systems, organizations can limit curveballs with equipment failure, avoid downtime and proactively address maintenance issues as they strive to keep operations running as smoothly as possible. PE Nelson Squires is the executive vice president and general manager of electrical and electronic solutions of Wesco International.

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ENGINEERING SOLUTIONS PREDICTIVE AND PREVENTIVE MAINTENANCE Brian Overton, Emerson, Knoxville, Tennessee

How to fulfill asset management needs with AI-based condition monitoring AI-powered analytics and automated condition monitoring are revolutionizing reliability. By shifting to continuous asset health monitoring, reliability teams gain real-time insights, predictive capabilities and the vast data sets needed to fuel AI engines.

T

Learning

Objectives

u

•P oint out the capabilities of AI for predictive maintenance, along with its limitations with respect to data collection.

•E xplain the difference between manual and automated data collection, including the advantages of the latter approach.

•D iscuss edge-based analytics and show how this technology can be used for a specific use case, namely vibration monitoring, one of the more common condition monitoring options.

he rise of artificial intelligence (AI) is generating a paradigm shift in industrial operations. The capabilities and potential of AI dominate headlines across the globe, with scientists, journalists and politicians speculating and exploring the many ways in which this new technology will change the world.

The process manufacturing industry is no exception to the influx of excitement around AI. Technology providers have gained a renewed enthusiasm for innovation, developing new use cases for neural networks and large language models almost daily. End users are leveraging those technologies for advanced analytics both at the edge and in the cloud, particularly in reliability, where AI tools can drive more effective predictive maintenance for better outcomes.

It seems as if there is nothing AI cannot accomplish, but that assumption is an illusion. There is one key thing AI cannot do: collect data from the field. For AI, data is everything. The AI agents that drive the best modern reliability technologies depend upon massive amounts of data — a need for hour-by-hour or even minute-by-minute data flow is not unreasonable for the most in-depth results.

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This insatiable appetite for data comes just as process manufacturing plants are facing a key challenge. As retirements claim the most experienced plant personnel, fewer new workers are taking their place. Not only are small, lean teams unable to collect the near-real-time data necessary to feed the technologies driving competitive advantage, many can barely find the time to collect the monthly data necessary to simply maintain awareness of the overall health of their assets.

To address this issue, most plants are moving away from manual, route-based data collection in favor of automated online condition monitoring. A combination of both wireless and wired condition monitoring sensors — with a varying array of capabilities — empowers reliability teams to set whatever cadence of data collection best fits their unique circumstances. This type of solution also prepares these teams to implement the modern technologies that will drive operational excellence and competitive advantage.

Route-based data collection falls short Historically, reliability teams have created scheduled routes to collect vibration data from assets on a regular cadence. A technician would visit each asset across the facility on scheduled days, with a handheld vibration monitoring tool and collect the data.

They would then bring it back to the main office where data analysts would pore over the spectrums and waveforms, tracking and trending asset health to identify issues that required attention.

Such a system has been in place for decades because it worked then and it still works now. The problem is, though it works, it is inefficient and leaves gaps in visibility that can decrease performance while increasing costs, time to repair and Plant engineering — www.plantengineering.com

7/28/25 10:00 AM

FIGURE 1: Edge analytics devices continuously collect data from assets and send it from the field directly to technicians and analysts.

Courtesy: Emerson

the likelihood of unplanned downtime. If a plant has thousands of assets and just a few technicians — not uncommon in these days of staff shortages — they may spend the first three weeks of a month collecting data and then analysts may need to spend the last week analyzing that data.

By the time the reliability team has results, a new month has started and they need to begin the process all over again. Additionally, if only 1% to 2% of those thousands of assets have a problem — a common situation — teams have spent a lot of time traveling around the plant just to confirm that most machinery is performing as expected.

Moreover, most route-based data collection is set at once a month, which creates another potential problem. If a technician visits a gearbox on the first of the month, collects data with the analyzer, then moves on, it is possible that a fault will start developing minutes or hours later. In such a case, if that fault continues to worsen over the next 29 days, it might create a blind spot that could lead to increased wear and tear on assets or even an unplanned outage.

For teams looking to shorten the time to analysis and delivery of actionable information, AI tools might seem to be the perfect fix. However, AI tools rely on a foundation of continuous, near-real-time data, so individual data points coming in every 30 days simply will not be enough. AI can help, but only if the data foundation is already solid.

Plant engineering — www.plantengineering.com

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Online condition monitoring Though it may not have received the attention that AI has experienced in recent years, online condition monitoring technology also continues to evolve. Many modern solutions exist, offering reliability teams a wide variety of options for collecting the more regular data necessary to free up personnel for higher value tasks and to feed their u analytics technologies.

One key technology used by reliability teams Condition monitoring for continuous data capture is wireless vibration insights u monitoring. A wireless vibration monitor can be Artificial intelligence is transforming industrial installed quickly and easily right at the asset, typireliability, but its success cally by a plant’s own technicians. Modern wireless hinges on access to frequent, high-quality data vibration monitors collect spectrum and waveform — something manual, data from balance of plant assets and send it directroute-based methods can ly to technicians and analysts from the field to no longer provide. eliminate the need for them to visit each asset and u To meet this demand, plants are adopting collect data. The most advanced wireless vibration automated condition monitors not only deliver raw data but also offer an monitoring systems that intuitive health score for each asset, providing decicontinuously collect and analyze data, enabling lean sion support to technicians of any experience level. teams to leverage AI for For assets needing additional insights, often predictive maintenance and improved operational those which rank higher in criticality, many teams performance. are installing edge analytics devices to collect conu By shifting to continuous tinuous data. Like wireless vibration monitors, asset health monitoring, edge analytics devices collect vibration data and reliability teams gain realtime insights, predictive send it — either via wireless signal or Ethernet capabilities and the vast cable — from the field directly to technicians and data sets needed to fuel AI analysts. However, edge analytics devices also conengines.

Insights

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ENGINEERING SOLUTIONS PREDICTIVE AND PREVENTIVE MAINTENANCE

tain on-board machine learning for deeper analysis at the edge.

Using built-in analytics, these devices can automatically identify common issues, such as imbalance and under-lubrication, in the most common assets: fans, motors, gearboxes, pumps and other rotating machinery. Additional features, like a hardwired power supply to ensure continuous data collection and the ability to automatically shut down assets when a problem is detected, make edge analytics devices a critical element of any continuous condition monitoring strategy (see Figure 1).

want to implement the newest AI technologies to capture competitive advantage and strive for top quartile reliability. In either case, reliability teams need a way to regularly collect data that does not require their personnel to spend hours in the field manually gathering it.

With lean teams, tight budgets and increased competition, technicians’ and analysts’ time can be better spent actively improving and maintaining plant equipment, rather than inspecting it. Continuous condition monitoring empowers teams to do just that, unlocking modern AI technologies and providing reliability personnel with the insights necessary to perform at their very best. PE

Condition monitoring improved with data FIGURE 2: Modern wireless vibration moniAchieving optimal plant performance tors can be installed quickly and easily right is dependent upon reliable access to good Brian Overton is the senior customer at the asset to collect spectrum and wavedata. Some teams simply want to improve enablement manager and subject matter form data and send it directly to technicians the efficiency of their reliability and preexpert for machinery health products for in the field. Courtesy: Emerson 25_006918_Plant_Engineering_AUG Mod: June 11, 2025 8:46 AM Print: 06/24/25 page 1 v2.5 dictive maintenance efforts. Others may Emerson.

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ENGINEERING SOLUTIONS

ENERGY EFFICIENCY AND MANAGEMENT Brandon Canclini, ABB, Fort Smith, Arkansas

Look at manufacturing emission reductions to achieve sustainability Plant and manufacturing engineers can pursue sustainability through innovative technologies and energy efficiency practices.

W

ith climate concerns becoming increasingly urgent, reducing emissions in industrial operations has become a business imperative.

The industrial sector accounts for nearly 30% of global CO₂ emissions, making it essential in the push toward net-zero.

This presents a challenge and opportunity for plant managers and engineers: how to drive operational efficiency while cutting carbon and staying competitive in a rapidly evolving industry. Companies with strong sustainability programs tend to achieve higher profitability than competitors.

Electrification, automation and data-driven optimization are empowering industries to redesign their operations and enhance efficiency.

From energy monitoring to predictive maintenance (PdM), these technologies are foundational for success in a low-carbon economy — enabling companies to improve performance while reducing emissions.

Sustainability isn't just good optics; it delivers measurable returns. Energy-efficient equipment reduces operating costs, PdM cuts downtime and smart automation can extend asset life. Over time, these improvements contribute to lower total cost of ownership and increase throughput. As energy prices fluctuate and carbon regulations tighten, plants that proactively modernize their operations will maintain compliance and strengthen the bottom line.

Plant engineering — www.plantengineering.com

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Accelerating the energy transition and sustainability Industrial transformation today is more than compliance — it’s about building smarter, more resilient systems that outperform in both sustainability and productivity. Electrification and automation are reshaping production environments, logistics networks and plant operations by cutting waste, reducing downtime and optimizing energy use.

At the core of this transition is a move away from fossil fuels. High-efficiency electric motors are engineered to reduce energy consumption across demanding applications. Smart automation

FIGURE 1: ABB has future-proofed its manufacturing facilities to allow for increases in production capacity without the need for physical facility expansion. Courtesy: ABB

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ENGINEERING SOLUTIONS ENERGY EFFICIENCY AND MANAGEMENT

FIGURE 2: Industries such as water/wastewater treatment are lowering emissions through various methods, including capturing methane produced during wastewater treatment and using it for energy, reducing the amount of energy used for treatment and implementing more efficient technologies. Courtesy: ABB

Learning

Objectives

u

• I dentify the key technologies — such as electrification, automation and predictive mainte-nance — that support sustainability and emissions reduction in industrial operations.

•E valuate the business benefits of implementing sustainability strategies, including improved efficiency, regulatory compliance and reduced total cost of ownership.

•R ecognize the importance of net-zero targets in manufacturing, such as reducing green-house gas emissions across operations and value chain.

platforms and industrial software enable real-time monitoring, control and PdM — improving uptime and optimizing plant operations.

Advancements in automation and electrification are central to a net-zero future vision, enabling smarter, more sustainable operations. But to fully realize these benefits, maintenance teams must adopt digital tools, monitor data from connected equipment and perform condition-based interventions. Upskilling in areas such as internet of things, energy management and sustainability best practices is therefore critical. Forward-thinking organizations are investing in training programs that empower technicians and engineers to actively contribute to the energy transition — turning sustainability goals into on-the-ground action.

Tackling emissions through innovation For plant engineering teams, reducing emissions — whether direct, indirect or value chain-related — is a complex challenge that demands advanced integrated solutions. In practice, this means implementing technologies to minimize fossil fuel dependence, increase operational efficiency and support circular business models. To achieve substantial progress, businesses must transition from fossil-fuel-based processes to electrical and techno-

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logical alternatives that detect and mitigate greenhouse gas leaks, such as methane.

To maximize impact, companies should focus on four key areas: • Energy efficiency: Technologies such as high-efficiency motors, energy management systems and smart grids help industries reduce their energy consumption and carbon footprint. Electrification of industrial processes further supports the reduction of reliance on fossil fuels.

• Carbon intensity reduction: By shifting to electric alternatives, industries can reduce their carbon intensity, particularly in sectors like manufacturing, transport and building operations. Electrified solutions and high-efficiency drives enable industries to minimize emissions across their operations.

• Waste and environmental footprint reduction: Innovative practices like lean manufacturing and circular design reduce waste and increase resource efficiency. Additionally, reducing emissions associated with production processes helps mitigate environmental impact.

• Enhanced circularity and flexibility: Adopting a circular economy approach, industries can design products for durability, reuse and recyclability, reducing waste and minimizing the environmental impact of end-of-life disposal. This approach also reduces resource dependence.

Addressing scope 1, 2 and 3 emissions Effective emissions reduction requires a focus on all three scopes defined by the Greenhouse Gas Protocol.

• Scope 1 — direct emissions: These emissions from owned or controlled sources by the company, such as fuel combustion in vehicles, boilers or other industrial processes. Companies can reduce Scope 1 emissions by adopting electric alternatives and optimizing operations.

• Scope 2 — indirect emissions from purchased energy: Scope 2 emissions come from the generation of purchased electricity. Reducing these emissions requires integrating renewable energy sources, improving energy efficiency and adopting energy management systems.

• Scope 3 — emissions from the entire value chain: Scope 3 emissions are often the most challenging, as they involve emissions across the entire supply chain. Reducing these emissions involves Plant engineering — www.plantengineering.com

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collaborating with suppliers to adopt sustainable practices, designing products for durability and recyclability and educating customers on the efficient use and maintenance of products.

Barriers to emission reductions, sustainability While momentum toward emissions reductions continue to build, the path to achieving sustainability goals remains challenging. Some of the top obstacles include: • Reliance on fossil fuels: Still accounting for over 80% of global emissions and transitioning away from them requires significant investments in renewable energy infrastructure.

• High upfront costs: Implementing energy-efficient solutions often involves high upfront capital costs, which can be a significant barrier for many small and medium-sized enterprises.

• Infrastructure limitations: Many existing systems are not designed to support modern technologies, creating a need for infrastructure upgrades.

• Budget constraints and data gaps: Access to accurate data is crucial for managing emissions.

Many companies lack the necessary tools to track and optimize energy use, making it harder to make informed decisions.

• Policy and behavioral hurdles: While policy changes are critical, there is also a need for widespread behavioral change across industries to embrace sustainable practices and innovations.

Overcoming these barriers requires a concerted effort from all sectors of the economy. Collaboration with suppliers, policymakers and technology providers is critical to creating an ecosystem that supports emissions reductions. By working closely with suppliers, companies can influence the sustainability of the materials they source and improve the energy efficiency of their entire supply chain.

Similarly, policy changes that support clean energy infrastructure and provide financial incentives for green technologies will accelerate the transition. Companies that engage with both suppliers and policymakers to drive systemic change can create a more sustainable and cost-efficient future.

Building a circular, low-carbon world A sustainable future depends largely on the transition to a circular economy — one that designs Plant engineering — www.plantengineering.com

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products and systems for durability, reuse and recyclability. By extending the lifespan of products and materials, industries can reduce waste, lower resource consumption and minimize emissions across the supply chain. This shift not only supports compliance with tightening environmental regulations but unlocks substantial cost-saving opportunities through improved resource efficiency and waste reduction.

Adopting circular practices strengthens supply chain resilience, reduces environmental impact and positions organizations for long-term competitiveness. Industry leaders are aligning with evolving regulatory and reporting standards — such as the EU Taxonomy Delegated Act, Global Reporting Initiative and SASB Standards — to set and exceed expectations.

FIGURE 3: ABB goes beyond carbon-neutral operations in its facilities, such as its Fort Smith, Arkansas, manufacturing plant and aims to eliminate and recycle the waste generated from manufacturing, service and logistics operations. Courtesy: ABB

Sustainability practices across all manufacturing fronts The journey to net-zero is a shared responsibility that requires action across all sectors — governments, policymakers, industry leaders and communities must collaborate to create the necessary conditions for a low-carbon economy. This includes creating supportive policies, investing in clean technologies and sharing best practices.

The path to net-zero is clear: every step taken u — whether by adopting energy-efficient technologies, shifting to electric systems or improving supSustainability insights u ply chain sustainability — moves industries closer Sustainability is now a core business driver to a more sustainable future. By embracing innoas industries confront vation and collaboration, industries can achieve climate challenges by elec-trifying operations, sustainability goals and play a leading role in the automating systems and global movement toward a low-carbon world. optimizing energy use to Every efficient motor, every electrified process, reduce emissions and boost efficiency. every avoided emission moves us one step closer. u Manufacturers that Manufacturing leaders should continue pushing prioritize sustainability forward because when industries lead, the planet not only lower their P thrives. E environmental impact

Insights

Brandon Canclini is the Global Product Manager at ABB.

but also unlock long-term profitability, resilience and competitive advantage in a low-carbon economy.

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ENGINEERING SOLUTIONS MATERIAL HANDLING

By James Taylor, OnRobot, Odense, Denmark

How off-the-shelf automation, material handling solutions can save time, money Off-the-shelf material handling automation delivers full price transparency and same-day deployments while boosting throughput and productivity.

FIGURE 1: Robotic palletizers powered by OnRobot’s D:PLOY platform are examples of complete, off-the-shelf robotic systems that are prebuilt, preconfigured and come with immediate availability. It’s a powerful alternative to “turnkey” systems that must be customized, programmed, integrated and deployed onsite, with workpiece changes often requiring the integrator to return and redeploy the system at additional cost. Courtesy: OnRobot

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W

hen Schrobbelèr B.V., producer of an iconic Dutch herbal liquor, was ready to automate its palletizing tasks, the company needed an approach that could seamlessly integrate into existing operations. Like many companies in the beverage industry, Schrobbelèr had determined that manual palletizing posed ergonomic and productivity challenges.

“Our production faced challenges with repetitive tasks,” said Jan Eijsermans, commercial director at Schrobbelèr. “Palletizing six-bottle boxes, each weighing 24.25 pounds was physically demanding.

We decided to automate this task to enhance efficiency and prevent potential physical complaints over time.”

However, for companies with limited in-house automation skills, like Schrobbelèr, traditional robot palletizing systems can be daunting. They are complex to program and use. And once deployed, they are not easy to redeploy on new products or palletizing formats without the burden of additional, ongoing integration costs.

Hidden costs, overt complexity Robot arms are just one component in a complete automated palletizing solution, that will include — at a minimum — a robot arm, one or more grippers, a user interface and programming.

To deploy a robot arm, companies need to hire an expert to scope, buy, integrate and program all the other components to create the required automated system. Weeks and months can be spent on this process, often at a cost that is multiple times the cost of the robot arm itself.

Moreover, when the robotic system is delivered, it can do only what it was initially programmed to Plant engineering — www.plantengineering.com

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do. So, when products change or a new size of box needs to be palletized, the integrator must revisit the facility to reconfigure and reprogram the system. All this means significant additional costs, including potential downtime for the manufacturer.

Because of traditional automation’s complexity and lack of cost transparency, many companies drop out at this first hurdle. These companies then must perform unergonomic material handling tasks like palletizing and machine tending manually — all the while facing the same labor shortage that’s impacting the global manufacturing sector.

What about turnkey solutions?

Making processes “turnkey” is an option, but turnkey solutions are not always quite as turnkey as the phrase implies.

These systems are engineered and branded for specific automation applications such as palletizing or machine tending. Typically, turnkey solutions include all the components required for those applications, albeit in some cases the components come as options at an additional cost. In many cases, a specific robot arm must be used, which limits the manufacturer’s choice.

But the heart of the issue with turnkey solutions is that only part of the system has been pre-engineered. The solution still must be customized, programmed, integrated and deployed onsite.

Moreover, future workpiece changes still require an integrator to return and redeploy the system at additional cost. Despite the implication that turnkey means an immediately available product, these partially engineered systems can have lead times almost as long as a fully custom solution.

Consequently, many companies, particularly those that lack in-house robotics experience, fall at this second turnkey hurdle as the complexity of deployment and the fluctuating, unpredictable nature of the ongoing costs involved make automating palletizing seem like a risky prospect.

Off-the-shelf automation and straight to work It’s not like the robotics industry is unaware of what manufacturers need and what many integrators and machine builders would love to be able to offer: complete, off-the-shelf robotic systems that are pre-built, pre-configured and can be put to work immediately.

Plant engineering — www.plantengineering.com

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This is the direction the automation sector is FIGURE 2: OnRobot’s partner Just Automate developed its headed in — and some off-the-shelf solutions are off-the-shelfOff-the-shelf, already on the market, such as the one chosen by standardized palletizer, Schrobbelèr.

MoveComponents on the “Installation was seamless — it only took us a D:PLOY platform, providing day and we were able to implement it during active an intuitive user interface that production without any disruptions,” said commerrequires no robotics expertise cial director Eijsermans. to operate. Courtesy: OnRobot "Right from the start, everything was clear and straightforward. We got detailed technical specs for the entire solution, a full list of components and a simple, no-surprises price. It made the whole process easy to understand and gave us confidence in u what we were getting."

Despite having to handle product variations in • Compare and contrast traditional robotic terms of bottle sizes, the automation is now manautomation and “turnkey” aged in-house, due to the ease with which the syssystems with complete, offthe-shelf robotic systems tem can be deployed. in terms of complexity, cost “I manage the palletizing system entirely on my transparency, lead time and own. I don’t have a technical background, so havease of deployment and redeployment. ing an easy-to-use solution was crucial for us,” said • Explain the benefits that Eijsermans. off-the-shelf automation It's a similar story at WEMAS Absperrtechnik provides to manufacturers, GmbH, a German provider of road safety products such as fully transparent pricing, immediate that deployed an off-the-shelf palletizer to unload availability, same-day pallets of heavy batteries — a labor-intensive task installation and the ability to manage workpiece changes that usually required two operators and typicalin-house without external ly took two full days to manually empty a single programming expertise. container.

• Identify how these “There are plenty of options in the market that solutions address challenges faced by claim to offer easy palletizing solutions,” said Julian manufacturers, particularly Döring, head of materials management at WEMAS. small- and medium-sized “But once you see a demo, it often becomes clear businesses, relating to labor shortages, lack of in-house they don't live up to the promise. This off-theautomation skills and the shelf palletizer was a completely different experineed for flexibility in tasks like palletizing. ence. What was demonstrated to us is exactly what

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we got — a smooth, sameday installation that delivered on our standards and expectations."

Because off-the-shelf solutions are a complete product, all the associated costs are clearly defined. This also means that pricing is fully transparent. These emerging off-the-shelf systems are FIGURE 3: WEMAS Absperrtechnik GmbH designed to help companies replaced a repetitive and unergonomic manual meet the needs of a specifdepalletizing task with an off-the-shelfOffic defined application such as the-shelf robotic palletizing solution powered machine tending, palletizing

by OnRobot’s user-friendly D:PLOY-platform. or packaging — and quickWith same-day installation, the solution ly. Deployment times are delivered $31,000 in annual cost savings at measured in hours, not days WEMAS. Courtesy: OnRobot and with clarity around pricing, companies of all sizes — and levels of robotics expertise — can invest in automation with confidence.

Palletizing is the leading application for this new generation of truly no-nonsense, easy to deploy automation. End users get an immediate, low-risk solution for their automation needs across a wide range of material handling tasks from palletizing to the “pick and place” elements of machine tending applications. More applications are expected soon, driven by innovation among machine builders and integrators. The rise of these new solutions will give manufacturing customers — and machine builders and integrators — powerful new tools to drive individual success as well as industry growth.

Truly off-the-shelf automation means that delivery and setup should be within a day, not days, weeks or months as is so often the case, even with turnkey solutions. And when businesses need to redeploy or adjust the cell, they can make the necessary adjustments quickly with existing staff — no costly and time-consuming programming or integrator visits required. PE James Taylor is the Chief Commercial Officer of OnRobot.

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ENGINEERING SOLUTIONS

MATERIAL HANDLING

Doan Pendleton, VAC-U-MAX, Belleville, New Jersey

How to determine the proper bulk material conveyance option There are differences between pneumatic, aero-mechanical and flexible screw conveyance technologies for dry bulk material handling. But which option is the best one for specific requirements?

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hen it comes to conveyance solutions for dry bulk materials, there are three major options. Pneumatic or vacuum, aero-mechanical and flexible screw conveyance options all have their pros and cons, but the materials being handled and the processes required for their processing all factor into the proper selection.

It’s important to consider the advantages and disadvantages of each bulk material handling solution.

Vacuum conveyance is ideal for dry bulk materials Vacuum conveyance is a form of pneumatic transport that uses negative pressure to draw materials through a sealed hose or pipe. It’s well-suited for clean, dust-free handling of dry powders, flakes and granules.

Whether receiving the material in 50-pound bags or bulk bags, pneumatic conveying uses pressure to draw the material from the source and bring it to the destination — whether that’s a packaging or processing line.

Vacuum conveyance systems offer an efficient and automated solution for handling dry bulk materials throughout the entire production process, from initial receipt to final processing, by significantly reducing the need for manual labor, enhancing worker safety, minimizing material spillage and contamination risks and improving overall plant efficiency. These systems are adaptable to various material types and containers, providing consistent, reliable transport while accommodating the unique flow characteristics of different powders and bulk solids.

Plant engineering — www.plantengineering.com

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FIGURE 1: AEROCON aero-conveyors are designed to convey bulk powders via tubular housings containing a continuous loop of steel cable with polymer discs attached at equal intervals along the steel cable. Courtesy: VAC-U-MAX

Learning

Objectives

u What are the benefits of pneumatic conveying?

Vacuum conveying systems offer numerous advantages that make them ideal for handling dry bulk materials.

These conveyance systems significantly reduce manual labor, eliminating the need for scooping, dumping and lifting by automating feeding and transfer processes. They enhance worker safety

• Define each bulk material handling technology.

• Learn how to automate bulk material handling by eliminating manual lifting and dumping.

• Recognize that not all dry bulk solids behave the same and understand why material characteristics matter.

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Aero-mechanical systems are well-suited for medium- to high-throughput applications and can handle moderate distances both horizontally and vertically. They offer a relatively low energy footprint compared to pneumatic systems and are easy to clean and maintain.

However, they may not be ideal for highly cohesive or fragile materials, and proper tensioning and alignment of the cable system are critical for reliable operation. Their balance of speed, efficiency and gentle handling make aero-mechanical conveyors a strong option for many industrial applications, including food, chemical and plastic processing.

FIGURE 2: Flexible auger conveying systems provide metered floor-level transfer of dry bulk powders from various sources including bag dump stations in an enclosed dustfree process. Courtesy: VAC-U-MAX

through closed-system designs that minimize dust emissions and improve overall plant air quality. The gentle conveying action preserves material integrity, reducing the risk of degradation for fragile products.

Additionally, fully enclosed pathways provide effective contamination control by protecting materials from airborne contaminants. Their flexible design allows seamless integration with a wide range of equipment, including bag dump stations, bulk bag unloaders, silos, mixers and packaging machines, making them a versatile solution for various production environments.

Aero-mechanical conveyance for free- or semi-free-flowing items Aero-mechanical conveyance is a versatile and efficient method for transporting dry bulk materials, particularly those that are free- or semi-free-flowing.

This technology uses a continuous loop of steel cable fitted with evenly spaced discs that travel at high speed within a sealed tube. As the discs move, they create an airstream that fluidizes the material, allowing it to be conveyed gently and quickly with minimal degradation.

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What are the benefits of aero-mechanical conveyance?

Aero-mechanical conveying technology offers several key benefits, particularly in industries that require efficient, reliable and dust-free material transport. It is highly efficient, minimizing energy consumption and reducing operational costs.

The conveyance technology is gentle on delicate or fragile materials, such as powders or food ingredients, ensuring minimal breakage or degradation.

Its compact design saves space, making it ideal for facilities with limited room, and its closed environment reduces dust, improving worker safety and meeting environmental regulations.

Aero-mechanical systems are flexible in layout, capable of operating horizontally, vertically or inclined and typically require less maintenance due to fewer moving parts. The enclosed system also reduces the risk of contamination, making it perfect for industries like food processing and pharmaceuticals.

With the ability to handle a wide variety of materials, including powders, granules and sticky substances, and supporting high throughput, aero-mechanical conveyors are an adaptable and efficient solution for many industries.

Flexible screw conveyance for bulk solids Flexible screw conveying is a method of transporting bulk materials through a tube using a rotating screw, or auger, inside a flexible, coiled shaft.

This technology is often used to move powders, granules, pellets and other bulk solids in industries such as food processing, pharmaceuticals, chemicals and plastics. The system consists of three main Plant engineering — www.plantengineering.com

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components: the flexible screw, which is the conveyor element; the tube that houses the screw; and the motor that drives the screw's rotation.

The flexible screw is made from a durable material that can bend and flex, allowing the system to be easily routed through complex plant layouts, including horizontal, inclined or vertical paths.

As the screw rotates, it lifts the material inside the tube and moves it from one point to another. The motion of the screw pushes the material along the tube, while the flexible nature of the screw allows it to adapt to various shapes and configurations without complex support structures.

What are the benefits of flexible screw conveyance?

Flexible screw conveying offers several key benefits that make it an attractive option for a variety of industries.

One of the primary advantages is its versatility, as it can handle a wide range of materials, including powders, granules and other bulk solids, with different shapes, sizes and densities. Its flexible design allows for easy customization of installation routes, whether horizontal, inclined or vertical, making it ideal for facilities with limited space or complex layouts.

The system is simple to operate and maintain, with fewer moving parts than traditional conveyors, which leads to lower maintenance costs and reduced downtime.

Additionally, flexible screw conveyors operate quietly and efficiently, saving both money and energy. They are also well-suited for environments where hygiene is a concern, as the enclosed system minimizes material exposure to contaminants. The easy-to-clean design makes them perfect for industries like food processing and pharmaceuticals.

Overall, flexible screw conveyance provides a reliable, efficient and adaptable solution for bulk material handling.

Comparing bulk material handling technologies When evaluating bulk material handling technologies, it's essential to understand the differences between pneumatic vacuum, aero-mechanical and flexible screw conveying systems.

Pneumatic vacuum systems use negative pressure to move materials through sealed pipelines, Plant engineering — www.plantengineering.com

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FIGURE 3: Pneumatic conveying systems increase productivity while reducing manual ingredient handling, lifting, stairclimbing and messy dumping by moving bulk powders from floor-level to up-and-over process equipment.

Courtesy: VAC-U-MAX

making them ideal for fine powders, granules and flakes, especially when hygiene, material containment and gentle handling are critical.

They are well-suited for long-distance and vertical conveying but typically come with a higher initial cost.

Aero-mechanical conveyors use a high-speed cable and disc assembly to create an air stream that transports materials, offering higher throughput than vacuum systems and handling a range of free- to semi-free-flowing materials efficiently over moderate distances and heights.

Flexible screw conveyors, on the other hand, feature a rotating helical screw inside a tube and are best for free- and some cohesive-flowing materials.

They are cost-effective, easy to install and capable of vertically conveying over short to medium distances, though they may pose a higher risk of material degradation.

Each system has unique strengths and limitations, and the best choice depends on the specific material characteristics, application requirements and facility constraints.

How to choose the right bulk material handling system Choosing the right bulk material handling system requires careful consideration of several key factors, including the type and sensitivity of the material, process requirements such as batch or continuous operation, the distance and direction the material needs to be conveyed, as well as the cleaning and maintenance demands of the system.

Additionally, space constraints within the facility and overall budget must be considered. Vacuum conveying is often the preferred solution when priorities include cleanliness, automation and effective material containment — making it particularly well-suited for highly regulated environments like pharmaceutical and food processing industries, where hygiene and product integrity are critical.

Insights

u

Bulk conveyance insights u There are key

differences between pneumatic (vacuum), aero-mechanical and flexible screw conveyance technologies for dry bulk material handling.

u The advantages

of each technology include reduced manual labor, improved safety, contamination control and flexibility.

u Certain material

characteristics, process requirements and facility constraints influence system selection.

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FIGURE 4: Mobile vacuum conveyance systems provide easy-to-use portable vacuum conveying and can be rolled in place over processing or packaging equipment to accommodate various discharge heights.

Courtesy: VAC-U-MAX

Choosing the right bulk material handling system is a critical decision that impacts every aspect of an operation, from worker safety and product integrity to throughput efficiency and regulatory compliance. Each conveying technology brings distinct advantages and limitations depending on the type of material being handled, the distance and direction of transfer, and the operational environment.

By thoroughly evaluating the materials' physical characteristics — such as particle size, flowability and bulk density — and aligning those with processing needs and production goals, a facility can make a more informed equipment selection.

The right system not only enhances operational efficiency but also reduces downtime, improves product quality, protects workers and ensures long-term cost savings. In a competitive manufacturing landscape, a well-chosen bulk material handling system is not just a convenience. It’s a strategic investment in a facility’s performance and future success. PE Doan Pendleton is the president of VAC-U-MAX.

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ENGINEERING SOLUTIONS

MOTORS, DRIVES

Paul Avery, Yaskawa America Inc., Waukegan, Illinois

A VFD user should know these induction motor calculations Understand more about alternating current motor specifications and calculations when using the motor with a variable frequency drive.

T

he benefit of using a variable frequency drive (VFD) is the ability to control an alternating current (ac) induction motor in a very specific way that will benefit various applications. Those benefits can be in energy savings, precise operation or operating the motor over a wide variety of speeds.

The relationship between the VFD and the motor begins before the VFD has even been selected. As a matter of fact, you can’t select the drive before you know what motor will be used on the application.

The ac motors come in various designs from the bread-and-butter Design B, four-pole, totally enclosed fan-cooled induction motors to the more recent permanent magnet and synchronous reluctance designs. Selecting the right motor for the job includes many considerations like the installation environment and available power.

The most important aspect is to know how much torque is going to be required to rotate the motor shaft to and move the application at the speeds needed. A mechanical engineer should do the math to figure out the “force at a radius” values. An article about motor calculations typically contains formulas for figuring out torque requirements for differing loads; this article doesn’t cover that detail.

Plant and industrial manufacturing experts should consider these five things to select or use an induction motor wisely: • Usng the motor nameplate • Easy way to figure out a motor’s capability • V/f curves for induction motors when using VFDs

Plant engineering — www.plantengineering.com

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FIGURE 1: Motor nameplate with variable frequency drive relevant information. Courtesy: Yaskawa America Inc.

• Constant torque and constant horsepower ranges • Accurate voltage when not using a VFD There is a simple way to get a pretty good estimate of the torque an induction motor can produce in footpounds. All we must know is the motor horsepower and the number of poles. For a four-pole motor, we can expect 3 foot-pounds per horsepower (hp). A 10 hp ac motor with a rated speed of around 1,774 revu olutions per minute (rpm) should produce about 30 • Understand how the foot-pounds We can check our estimate by looking at information on the motor a motor nameplate (see Figure 1). nameplate details overall The nameplate shows that if you supply the motor capabilities. motor with 460 volts ac (Vac) at 60 hertz it will • Learn how applied speed draw 13.5 amps and run no slower (slip) than 1,774 affects alternating current motor torque producing rpm while producing up to 29.5 foot-pounds. It capability. seems our motor torque estimate is fairly accurate • Know how not applying (0.5 foot-pounds off). The estimate works just as the motor’s rated voltage well for six-pole (4.5 foot-pounds per hp) and twoaffects the motors’ pole (1.5 foot-pounds per hp) motors as well. performance.

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FIGURE 2: Torque and power versus speed. Courtesy: Yaskawa America Inc.

efficient and overheat. Look at both the motor power and the motor torque versus frequency when the motor is driven by a VFD (see Figure 2). The graphic is a visual representation of the formula: hp = (T * N) / 5,250 It’s a simple enough equation to represent that horsepower is a product of torque (foot-pounds) times speed (rpm) over a constant. It is very common to reconfigure the equation to solve for torque as a product of horsepower times a constant over the shaft speed.

T = (hp * 5,250) / N

FIGURE 3: Torque OK/not OK at 75 Hz. Courtesy: Yaskawa America Inc.

‘

There is a simple way to get a pretty good estimate of the torque an induction motor can produce in foot-pounds.

’

How a VFD can affect speed Another consideration about using a motor is speed range. Motors have safe operating speeds that align with the mechanical components like bearings and what they can withstand as far as revolutions per minute.

A different speed range to consider is the range of speeds at which the motor can produce its rated torque at when used with a VFD. A VFD can change both the voltage and the frequency that the motor will receive. The ability to produce constant torque at any speed up to the frequency rating of the motor is not based on just the voltage being sent from the VFD to the motor. Rather, the ability stems from keeping an optimal volts per hertz (V/f ) ratio.

The volts per hertz ratio helps determine the magnetic flux density inside the motor. If the volts per hertz ratio is too low, then the density isn’t sufficient to produce the motor’s rated torque. Conversely, if the ratio is too high (too much voltage), the fields become saturated, but torque doesn’t increase. If anything, the motor may become less

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The first formula explains why the power climbs as the frequency increases (N) and saturates when the motor reaches its rated frequency (60 Hz). The second formula explains why after the horsepower becomes constant, the torque must drop off at one over the speed (1/f, if you prefer). This is referred to as the constant horsepower range or sometimes even the field weakening range.

How VFDs can help torque If you know what a volts per hertz pattern is in a VFD, you can understand how VFDs will keep a constant V/f ratio (around 7.5 to 1 for a 460-volt motor) to optimize torque. Once the VFD runs out of line voltage, but the frequency continues to increase, the motor is forced to lose torque capability because the magnetic flux field is weakening.

If the user plans to run an application over the motor’s rated frequency, it is prudent to figure out what torque will be necessary at their maximum speed. For instance, if the fan wall needs to run at 75 Hz to create the necessary air flow but the motor’s rated frequency is 60 Hz, a user will need to know what the necessary torque requirements are at 75Hz before you make any motor or VFD selections (see Figure 3).

We can at least ballpark the new larger motor drive combo by going back to the first formula.

We can solve for horsepower by using what torque in foot-pounds we require while at a higher rpm.

We can approximate the new rpm at 75 Hz to be about 2,218 rpm. We can use our 29.5 footPlant engineering — www.plantengineering.com

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‘

The manufacturer makes no

FIGURE 4: How

guarantees about how the

motor voltage

motor will perform if any of

performance:

variations affect Courtesy: EASA

the values are not at the rating, particularly voltage.

’

pounds we saw on the earlier motor nameplate as our desired torque. hp = (29.5 * 2,218) / 5,250 = 12.5 hp Unfortunately, manufacturers do not make 12.5 hp motors, so a 15-hp motor and its matching VFD would be used. The system can achieve the torque needed at the speeds necessary to run.

Avoiding failures by using VFDs Stepping back from VFD usage, examine what happens to motors when they are not run by VFD and are not getting their nameplate-rated voltage. As mentioned earlier, the information on the motor nameplate is very particular. All of the values are dependent on the motor getting the power it was designed for. The manufacturer makes no guarantees about how the motor will perform if any of the values are not at the rating, particularly voltage.

Most industrial motors in the U.S are rated at 230 or 460 Vac (or dual-wound 230/460). The actual average line supply voltages tend to be 240 or 480 Vac across the country. And some areas will actually have their 480 volt supplies run even higher than that depending on how much local load there is and how far from the substation they are.

According to ANSI C84.1-2020: Electric Power Systems and Equipment - Voltage Ratings (60 Hz) National Steady State Voltage Regulation Standards, -5% to +5% variation is allowed on 480 Vac. That puts the voltage potentially up around 504 Vac. So, what happens when you apply 500 Vac to a motor designed for 460 Vac? EASA supplies details to predict graphically what will happen to Plant engineering — www.plantengineering.com

PLE2508_MAG_MOTORS_YASKAWA_V4msFINAL.indd 41

the motor performance based on voltage variation (see Figure 4).

Mathematically, if we feed that 460 V motor 500 V, we are at nearly 109% of the motors rated voltage. According to Figure 4, at +9% we will gain extra motor torque but at the expense of u nearly 5% increase in full load amps and almost VFD insights 10% increase in starting amps. This will affect the u Using a variable sizing of starters, overloads and cabling. Motor frequency drive (VFD) heating will increase and premature motor failure allows precise control of is likely as well. alternating current (ac) induction motor speed There are ways to deal with high voltages like and torque, optimizing transformers and line reactors. Possibly the best performance and energy efficiency across a way to deal with high voltages is to use a VFD. wide range of industrial VFDs are manufactured to deal with 480 Vac plus applications.

10% without failure. The voltage that is passed to u Selecting the right the motor is not pinned to the voltage at the drive motor and understanding its torque requirements are input but based on the VFD’s programming, i.e., essential before choosing the V/Hz pattern we mentioned earlier. The VFD a VFD, which can also P can give the motor exactly what it was rated for. E help regulate voltage and

Insights

Paul Avery is a Senior Product Training Engineer at Yaskawa America Inc.

maintain motor health, especially in environments with fluctuating power supplies.

July/August 2025

| 41 7/28/25 10:06 AM

ENGINEERING SOLUTIONS MOTORS, DRIVES

Jared Scott, SEW-EURODRIVE, Lyman, South Carolina

Motor calculations made simple: optimizing performance and efficiency Motor selection starts with accurate calculations. From power and torque to duty class and efficiency, properly sizing and specifying a motor is essential to building a reliable, energy-efficient drive system.

S

FIGURE 1: This illustrates the motor duty classes

electing the right motor is like choosing the right engine for a vehicle. A car engine in a semi-truck might get the job done briefly, but it won’t last long, just like an undersized motor in a demanding application.

Similarly, an inefficient motor is like a car with a leaky fuel tank — it wastes energy and money every time it runs.

Choosing the wrong motor can lead to inefficiency, overheating or even premature failure.

Here are key factors to consider: Power requirements (horsepower, or hp): Power reflects the motor’s ability to handle the load under both operational and peak conditions.

Under-sizing risks motor failure, while oversizing leads to energy waste. Think of it this way:

and example applications. Courtesy: SEW-EURODRIVE

an overpowered motor running constantly is like leaving the lights on in every room of your house when you only need one lamp.

Torque and speed: Torque (pounds per foot) is the motor’s twisting force (F) and speed (revolutions per minute) determines how fast it spins.

Constant torque applications: Conveyors and mixers require steady force regardless of speed.

Variable torque applications: Fans or pumps require less torque at lower speeds, making them ideal for energy-saving strategies.

Duty class: Duty classes describe how often and how long a motor operates under load.

Choosing the wrong duty class can lead to overheating or unnecessarily high costs.

S1 (continuous duty): Full load for unlimited time (e.g., conveyor belts or pumps).

S2 (short-time duty): Full load for a fixed period, then cooling (e.g., cranes or hoists).

S3 (intermittent duty): Cycles on and off to prevent overheating (e.g., compressors).

S4 (intermittent duty with starting): Includes frequent starts, perfect for elevators or material handling systems.

Efficiency (international efficiency, or IE): Efficiency determines how well a motor converts electricity into work. Higher efficiency motors (IE3, IE4 or IE5) reduce energy waste over time.

Environmental conditions: Motors exposed to dust, moisture or heat require appropriate enclosures and cooling systems to maintain performance and reliability.

Practical motor example: conveyor system in a warehouse To illustrate these principles, let’s examine a warehouse conveyor system. A conveyor must move 1,100 pounds of boxes at 164 feet per minute for 8 hours daily. This is an S1 continuous duty application.

42 | July/August 2025 PLE2508_MAG_MOTORCALC_SEW_V2msFINAL.indd 42

Plant engineering — www.plantengineering.com

7/28/25 10:08 AM

Learning

Objectives

u

• Understand how to perform basic motor calculations —

including power, torque and speed — to accurately size a motor for specific load and duty cycle requirements.

• Identify key motor selection criteria such as duty class, efficiency ratings (IE standards) and environmental conditions and understand their impact on performance, reliability and energy consumption.

• Evaluate the benefits of integrating motors with gear units and variable frequency drives (VFDs) to optimize system efficiency and reduce long-term operational costs.

F = 1,100 pounds x 0.1 = 110 pounds Find the power: Power (hp) = (Force (pounds)x Conveyor speed (feet/minute))/33,000 hp = (110 pounds x 164 feet/minute)/33,000=0.547 hp Add a safety factor: 0.547 x 1.25 = 0.684 hp A 1 hp motor rated for S1 duty is ideal for this application.

STEP 2: Select the motor Selecting a high-efficiency motor rated for S1 duty ensures reliable operation while reducing energy costs.

FIGURE 2: A conveyor system showing the motor, helical-bevel gearbox and conveyor belt, with annotations for torque and power.

Courtesy: SEW-EURODRIVE

For smaller motors, Annual energy cost by motor efficiency like a 1 hp motor run$1,200 ning 8 hours/day at $1,000 $0.10/kWh, the annual $800 cost is $262. Switching to $600 an IE3-rated motor can $400 save $26/year. Across a $200 facility with dozens of motors, these savings $0 Standard IE3 IE4 IE5 quickly add up. efficiency Motor efficiency Selecting the right motor isn’t just about power ratings — it impacts FIGURE 3: This bar energy costs, system reliability and operational chart compares annual performance. While the examples here apply unienergy costs of stanversally to motors, gear units and VFDs from any dard efficiency, IE3, manufacturer. By considering duty classes, load IE4 and IE5 motors, types and integration with compatible components, highlighting the savyou can design systems that save money and deliver ings of higher efficienlong-term results. PE Annual energy cost

STEP 1: Calculate power requirements Determine the F needed F = load weight x friction factor Assuming a friction factor of 0.1

STEP 3: Gearbox and variable frequency drive (VFD) integration A helical-bevel gearbox adjusts the motor’s outJared Scott is the National Training Manager at put torque to meet conveyor requirements.

SEW-EURODRIVE. A VFD optimizes speed during lower-demand periods, reducing energy consumption by up to 30%. u

cy motors. Courtesy: SEW-EURODRIVE

Insights

Motor efficiency and cost savings Motors consume a significant portion of their lifetime costs in electricity. For example: A 50 hp motor running 24/7 at $0.10/kilowatt hour (kWh) can cost more than $33,000/year in electricity.

Upgrading to a high-efficiency motor reduces energy consumption by 10%, saving $3,300 annually.

Plant engineering — www.plantengineering.com

PLE2508_MAG_MOTORCALC_SEW_V2msFINAL.indd 43

Motor insights u Selecting the right motor is critical for ensuring efficiency,

reliability and cost savings in industrial applications, as it must match the specific load, duty class and environmental conditions of the system.

u This guide simplifies motor calculations, explains key

concepts like duty classes and load types and highlights how integrating motors with gear units and variable frequency drives (VFDs) creates a reliable and efficient drive system.

July/August 2025

| 43 7/28/25 10:08 AM

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