Metal Work ISO 6432 pneumatic air cylinders offer an ideal solution for metric applications where an inexpensive actuator is desired. They feature a magnetic piston for position sensor compatibility.
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Metal Work heavy-duty metric dual guide rod cylinders are ideal for applications requiring precision mounting and tolerance to a sideload. These cylinders feature magnetic pistons, bronze bushings, anodized extruded aluminum alloy housing, and switch mounting tracks.
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VIEWPOINT
| Can using AI make your company successful?
Artificial intelligence (AI) isn’t magical, but can it help companies succeed in business?
INSIGHTS
Get cutting-edge automation
from
panel offers advice on automation trends.
SOLUTIONS
Preventive maintenance keeps systems reliable, energy-efficient and compliant.
Predictive maintenance is a critical part of sustainable operations.
To achieve leak-free performance, understand what factors help improve gasket performance.
How to achieve plant sustainability goals through energy monitoring
Monitoring gives manufacturers visibility and control to drive environmental initiatives.
| Boosting compressed air efficiency: Practical ways to maximize a system
There are practical strategies to boost compressed air efficiency.
| Ways to modernize lubrication systems in rotating equipment
Effective lubrication is required to properly maintain the reliability of rotating equipment.
| How robots maximize workforce efficiency and automation
Robots can boost manufacturing efficiency by automating demanding tasks.
| Robots offer efficiency, flexibility, safety on the plant floor
Industrial robot technology offers manufacturers a clear way to improve efficiency and profitability.
| Are autonomous mobile robots right for your plant?
Autonomous mobile robots (AMRs) might not be right in your facility; it’s smart to consider options.
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AMANDA PELLICCIONE, Marketing Research Manager A Pelliccione @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
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• Artificial intelligence in manufacturing
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• Expert Q&A: Maintenance
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• Oils and lubrication
• Plant automation
• Preventive maintenance
• Pumps
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• Valves and seals
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Can using AI make your company successful?
AI isn’t magical, but it appears to be helping companies succeed in business.
Afriend and I were discussing artificial intelligence (AI) recently, and she commented that because AI was so new, there really wasn’t anything mentioned in cultural references until just a few years ago. I was confused. She’d used Apple’s Siri for several years and owned an Alexa device, however she didn’t think AI was relevant to the masses until tools like ChatGPT came into play.
for about 75 years, and it was adopted by the manufacturing industry about 50 years ago.
Amara Rozgus, Editor-in-Chief
That assumption deserves a closer look. AI has been around for quite some time. While she and I hadn’t yet been born when the movie came out, “2001: A Space Odyssey” was the first memory that I held of AI. Watching it with my uncle and realizing that computers could make (debatably smart) decisions seemed logical to me. “WarGames” is another frequently referenced film of interest to anyone in cybersecurity, technology, programming and AI. It came out in 1983, well before AI became popular in modern vernacular.
The first references to AI in movies was in the 1927 silent film “Metropolis.” A quick search shows that it’s been part of our imagination and history for nearly 100 years. Why does it feel newly urgent?
Machine learning has been part of manufacturing plants for some time, analyzing data from sensors to optimize processes or eliminate failures. The general concept has been around
While I showed her that AI had been around in some form for quite some time, the use of the current generative and process AI isn’t consistent. Reports vary; a November 2025 McKinsey study indicates that most respondents (nearly twothirds) are simply experimenting with AI. When broken down by business function, manufacturing was at the bottom of the list, with 91% not using AI at all. That said, manufacturers who are using AI had a cost decrease of less than or equal to 10% most of the time.
The 10th Annual State of Smart Manufacturing report from Rockwell Automation indicates that 56% of respondents are piloting smart manufacturing, 20% are using it at scale and 20% are planning to invest.
The report also highlights the many risks and concerns held by manufacturers, and many of these are echoed across different industries.
What does this mean for companies navigating a fast-changing landscape? It suggests that although concerns persist, AI will continue to embed itself into core business practices. Adoption will vary, as it does with any emerging technology, but the trajectory is clear: AI will be increasingly impossible for companies to ignore. PE
Get cutting-edge automation insights from experts
Our panel of automation experts offer advice on automation trends, how manufacturers are scaling automation against economic uncertainty and what to watch in 2026.
Q: What are the most significant automation trends shaping plants in 2025?
Heath Stephens: In many ways, automation trends in 2025 were shaped by two opposing forces: the constant drive to increase efficiency and profitability and companies' hesitation to invest with an uncertain economic outlook. This year was certainly a year when more companies started to look at how generative artificial intelligence (AI), like ChatGPT and others, could be more directly used
in industrial applications. While not replacing special-purpose industrial AI applications, Gen AI will give us new ways to interact with our processes and sort through data.
Steve McGowen: The most common trend that I have been involved with, across multiple industries, is automating customers’ machine monitoring. This allows maintenance and reliability departments to focus their most valuable resource — labor — on day-to-day operations instead of periodic checks that may not be needed at that time. It also brings valuable data that allows these teams to mold their preventive maintenance and inspection programs to fit their specific equipment and facility needs. These systems can be scalable to gather both equipment and atmospheric data on the plant floor, which is useful for converting from a run-until-failure thought process to a truly predictive mindset.
Geert van der Zalm: Implementation of highspeed conveyance moving from electronics manufacturing towards automotive, enabling significantly faster throughput time and integration of process steps into the conveyance motion.
Sean Saul: In 2025, it was the year that software-defined automation technologies for mission-critical workloads went mainstream. Beyond virtualization of workstations and servers, the introduction of virtualized controllers deployed on high-performance computer platforms represents a huge opportunity to deliver on the promise of flexible manufacturing. Edge technologies expanded on this theme as installations of platforms that support both real-time and optimization workloads demonstrate clear and measurable value.
Q: How are manufacturers balancing automation investments with economic uncertainty?
Cody Bann and John Oskin: Currently, industries are facing economic uncertainties and manufacturers are no exception. Our processing clients are challenged with increased costs for raw materials. To help offset these expenses and improve
FIGURE 1: Automation can increase efficiency and profitability across manufacturing disciplines, powered by artificial intelligence and other technologies. Courtesy: Hargrove Controls & Automation
Participants
Objectives Learningu
• Discover the latest trends in plant automation.
• Learn how manufacturers are scaling their automation strategies in the face of economic uncertainty.
• Determine which automation trends will be worth watching in 2026.
productivity, companies are implementing digital transformation initiatives, which can improve plant performance by as much as 10% to 20%.
Significant labor and skills gap issues, lingering supply chain challenges and the current economic uncertainty can be daunting. However, evaluating the strategic plan and shifting it with the business environment is critical to meeting goals. Two key questions leadership should ask: Did we keep up with technology? Did we invest in the right equipment?
We, along with our systems integrator partners, are reiterating to our manufacturing clients the tremendous benefits of how upgraded technology will increase efficiencies, improve quality control and that a better working environment with a more modern facility helps retain younger workers. A modernized plant also allows companies to tap into new business models, including customization and on-demand manufacturing.
Sean Saul: Automation continues to be one of the highest return-on-investment (ROI) levers for manufacturers to increase productivity. Amid growing economic uncertainty, there’s been an increased emphasis on how quickly automation investments pay back, driving demand for software solutions that deliver faster time to value.
Heath Stephens: Many manufacturers have postponed investments until they better understand future economic conditions. Obviously, this is a broad generalization. There are still thriving industries and businesses in more challenging sectors with well-defined market niche and a robust outlook. However, we have seen quite a few clients notice their market outlooks sour or become unclear, leading to postponed investments. This makes sense in some cases, but in others, clients are missing out on unrealized operational savings that could generate funds for them in 2026 and beyond. Companies should take a closer look at their automation investments. If they are unsure of the original plan, take a step back. Does it make sense to do
Cody Bann, Vice President and John Oskin, Senior Vice President SmartSights Round Rock, Texas
a partial project with a decision on just the larger scope held back? Should the planned investment be shelved in favor of an alternative investment? For example, maybe the rate improvement effort isn’t needed yet, but improvements in first-pass quality and improved reliability are still beneficial.
Geert van der Zalm: Automating processes is essential to stay competitive in the market. It unlocks levels of efficiency and productivity that manual processes will never be able to reach. As consumer demands continue to rise, automation will be the key to increasing throughput with accuracy and consistency. Automation doesn’t have to be zero to 60 though. Companies can opt to adopt automation slower, perhaps moving from manual to semi-automated before taking the plunge to full automated processes. This slower shift provides the opportunity for companies to establish an ROI for the change and make the case to continue the automation journey.
Q: Which industries are currently leading in plant automation adoption?
John Oskin, Senior Vice President SmartSights Round Rock, Texas
Geert van der Zalm Vice President of Assembly Technology Bosch Rexroth Charlotte, North Carolina
Steve Kenney, Director of Artificial Intelligence (AI) Product Management
Sean McGowen, Account Specialist, Electrical Motion Automation New Bern, North Carolina
Sean Saul Vice President of Product Emerson Austin, Texas
FIGURE 2: Quasar Energy Group turns waste into gas that can be used to produce electricity and thermal energy. This diagram illustrates this process and shows some of the components monitored with WIN-911 remote alarm notification software. Each sensor feeds information to Rockwell Automation’s FactoryTalk SCADA system. Courtesy: SmartSights
Geert van der Zalm: We’re seeing a big push for automation in the automotive industry. Automotive, battery and medical manufacturers must increase throughput on key assembly processes to keep up with consumer demands. As we enter 2026, we expect other industries to follow suit as the need for greater efficiency is required to stay competitive in the market.
Q: How is AI being applied to plant-floor operations today?
Sean Saul: AI continues to evolve in the traditional areas of strength like advanced process control and equipment health. New advancements in models and supporting frameworks are increasing the accuracy and long-term sustainability of these techniques. The emerging segment for generative AI on the plant floor is the use of natural language advisors to upskill personnel in context and realtime, increasing situational awareness and delivering expert guidance where it matters most.
Q: What role does machine vision play in quality assurance and defect detection?
Steve Kenney: Our onsite machine vision system deployments have become the cornerstone of our customers’ modern quality assurance by bringing speed, accuracy and consistency to the inspection process. By using high-resolution cameras and intelligent software, these systems scan every product in real time to catch defects like
scratches, misalignments or incorrect labels that human eyes might miss. Unlike manual inspection, machine vision applies the same objective criteria to every part, reducing variability and eliminating fatigue-related errors. One thing machine vision users learn quickly is that these systems provide instant feedback when issues arise and collect valuable data to improve processes over time. This combination of reliable detection, actionable insights and traceability helps manufacturers reduce waste, ensure compliance and deliver the quality level that today’s customers expect.
Heath Stephens: Machine vision is an incredibly powerful tool in quality assurance and defect detection. Modern systems can run at very high image processing rates, relying not just on visible wavelengths but also on UV, Infrared and X-ray images. Sonar and other synthetic imaging technologies can also be used. It’s also easier to integrate these technologies into cloud platforms for further analysis, record retention, etc.
Q: How is generative AI influencing engineering and automation design processes?
Sean Saul: Engineering functions are being transformed by the power of large language models as they have proven very adept at structured text translation, like control narratives to code and one code to another. When combined with process and domain expertise, this capability can dramatically boost engineering productivity.
Computer vision is also being used to directly digitize and create operator graphics from P&IDs and when combined with advanced operator display knowledge, this approach can automatically generate graphics in a fraction of the time compared to the traditional methods. Generative AI can also aid value engineering when integrated with 3D conceptual design tools, as an example by automatically optimizing piping layout based on economics and physical constraints.
Q: How are robotics being used beyond material handling and assembly in 2025?
Geert van der Zalm: Cobots are being used for a wider range of industrial applications than ever, especially with the introduction of 7-axis robots,
which offers an extra degree of freedom from traditional 6-axis cobots. Through our subsidiary, Kassow Robots, we’re seeing cobots being used outside of more well-known applications like palletizing and pick and place and being implemented for welding, CNC machine tending and quality inspection applications.
Q: What progress has been made in predictive maintenance and condition monitoring?
Heath Stephens: Predictive maintenance and condition monitoring tools have been around for a while and the core mathematics behind the scenes is well-established. However, there continue to be new improvements in usability and pricing that make these tools more accessible and practical than ever before. Whether you need an edge computing solution, server-based system or a hybrid cloud platform, predictive maintenance tools can help you optimize the impact of your maintenance workforce. No one has unlimited maintenance bud-
gets and a production line under maintenance isn’t usually functional for production. Predictive maintenance tools can help make sure maintenance is both timely and effective.
Steve McGowen: Advances in sensors are giving us more data points to measure in increasingly convenient packages. Manufacturers are adding extra axes of vibration analysis to sensors, combining multiple sensors into one housing for ease of installation and having all this recorded data in a user-friendly, customizable and easily translatable user interface. The easier a program is to use, the more likely it will be continued. This simplicity is encouraging more companies to invest in and utilize these technologies.
Q: How are plants using digital twins in daily operations?
Sean Saul: Digital twins are increasingly becoming the foundation of robust optimization programs. Traditionally used to emulate control system
‘Engineering functions are being transformed by the power of large language models as they have proven very adept at structured text translation, like control narratives to code and one code to another.’
‘
functions and validate changes to control schemes or logic, their integration with high-fidelity models and training software now enables a seamless, safe environment for deploying optimization techniques, measuring impact and smoothly embedding improvements into ongoing operations.
Cody Bann and John Oskin: Digital twin technology models production lines and combines with real-time data collection to monitor processes, detect downtime and predict performance, helping manufacturers identify root causes of problems and improve efficiency.
By leveraging this digital twin technology, manufacturers have access to sophisticated analytics that can be visualized on shop floor HMIs.
Digital twin technology provides a live visual representation of production lines, highlighting issues like machine failures or bottlenecks with machine state and process and linked process flow to show fault propagation. Digital twins deliver an up-to-date digital record of physical assets so engineers and plant managers can quickly identify key factors that foreshadow the need for preventative repairs or maintenance. This technology can be used to optimize tool calibration, load levels and even cycle times, allowing companies to increase their operational efficiency while significantly reducing costly downtime or equipment malfunctions.
Digital twin technology supports data validation, accurate calculation of key performance indicators (KPIs) like mean-time-between-fail (MTBF) and mean-time-to-repair (MTTR) and provides insights from the plant floor to the executive level, driving them toward a smart factory and Industry 4.0 goals.
Geert van der Zalm: Process simulation software such as Visual Components enables manufacturers to test a design via simulation and adjust before implementing. When working in conjunction with robust design software, this helps simplify the automation process from initial design to simulation to final system and helps ensure daily operations run smoothly once a new system is implemented.
Q: How are manufacturers reskilling workers to work alongside automation?
Geert van der Zalm: With automation, manufacturers can focus on training their employees to optimize machine productivity and gain additional skills to keep machine uptime.
Q: Are manufacturers seeing measurable ROI from automation upgrades in 2025?
u
Insights
Automation insights
uArtificial intelligence (AI) is helping manufacturers drive efficiency and prioritize preventive and predictive maintenance.
uDigital twin technology is rapidly evolving and becoming a must-have for manufacturers.
uLegacy systems are being integrated with new automation technologies to betterstreamlineprocesses.
What makes ABLE so powerful is its ability to integrate real-time IoT edge data into business systems such as manufacturing execution system (MES), supervisory control and data acquisition system (SCADA) and enterprise resource planning systems (ERPs). This integration helps speed up the process of Production Line Modeling by reducing the need for manual tagging by more than 80%.
By leveraging this digital twin technology, manufacturers have access to sophisticated analytics that can be visualized on shop floor HMIs. This helps provide insight into how processes are always working, making it easier to diagnose problems before they become major issues and identify process improvements that could lead to greater product line efficiency.
Steve McGowen: Manufacturers who have implemented sizable automation upgrades are seeing ROI in the form of labor savings. Multiple manufacturers we have worked with shared this same experience with us. Some simply look at this labor reduction as a cost savings, while others reallocate the labor saved to more important or crucial tasks. While each company utilizes this labor savings differently, there is a measurable return from these projects.
Cody Bann and John Oskin: The short answer is yes and here’s why. By deploying advanced technologies, manufacturing plants can accelerate and drive overall equipment effectiveness uplift, avoid problems before they occur and reduce engineering time by up 70%. We regularly benchmark performance using real-time data. Last year one of our studies revealed that for a $1 billion company, every one percent improvement in overall equipment effectiveness — like integrating advanced software that reduces equipment downtime — is worth approximately $7 million annually.
When manufacturers integrate a manufacturing execution system (MES) it provides real-time visibility across all levels of production. These systems monitor work steps ranging from equipment, materials, data collection and both automated and manual processes — continuously making sure that people and equipment are operating according to policies. MES technology gives organizations the ability to take responsive action when it comes to data-driven events occurring on the production chain. Unfortunately, because it’s a steep hill to climb, not every manufacturing plant implements MES. High implementation and operational costs, complexity and inflexibility mean that some facilities are unable to take advantage of the powerful MES systems out there.
However, third-party MES accelerators support and complement this market by providing a solution that is fast to deploy, simple to configure, easy to use and cost-effective for all lines and sites. Organizations can realize quicker ROI as they work towards a complete MES solution. Manufacturing teams can bypass lengthy development efforts and get an intuitive solution running in days instead of months.
Q: How are automation vendors responding to the need for more flexible production lines?
Geert van der Zalm: Modular components that enable the greatest possible degrees of freedom when it comes to layout planning and use of space. An example of this in the industry is our conveyance line, which features a robust portfolio of components that can be adjusted to the requirements of a diverse range of industries. This flexibility is key to ensuring an efficient and economical conveyance solution for every application.
Steve Kenney: We work with many automation suppliers and see a shift from rigid, single-purpose systems to modular robotics, collaborative robots and adaptable control platforms that can be reconfigured quickly as production needs change. This is true especially for high-mix, lower-volume applications, which are becoming more prevalent today. Under the umbrella of artificial intelligence (AI), deep learning machine vision systems now let equipment recognize and adjust to different parts on the fly, which is important for those high-mix, lower-volume needs. We have deployed the use of digital twins and simulation tools that allow teams to model and test changes virtually before making them on the floor. Together, these technologies are helping manufacturers build production lines that adapt faster, reduce downtime and stay competitive in fast-changing markets.
Q: How are legacy systems being integrated with modern automation platforms?
Geert van der Zalm: To integrate legacy systems with modern automation platforms, we typically leverage communication standards like OPC Unified Architecture to bridge the technology gap, facilitating data exchange with modern IT systems such as cloud computing platforms.
Heath Stephens: Automation engineers have always been integrating “legacy” systems with “modern” platforms. Many formerly modern platforms are now considered legacy systems to be integrated. The rise in popularity of Ethernet communications 20 years ago made integrating multiple platforms much easier. This, coupled with the adoption of communication protocol standards (Modbus TCP, Ethernet/IP, OPC, etc.), meant less custom wiring and coding custom drivers, making integration much simpler. One of the biggest issues with many legacy systems is a lack of instrumentation. Since automated controls were more expensive per point, machinery and processes often had fewer instruments, especially analog signals. This means the data available for the machinery health diagnostics and process insights may be missing. Fortunately, there are ways to add instrumentation, either with industrial internet of things (IIoT) add-on devices, wireless instruments, clamp-on meters or other more traditional instrumentation. PE
ENGINEERING SOLUTIONS
PREDICTIVE & PREVENTIVE MAINTENANCE
Jayme Leonard, Atlas Copco Compressors, Rock Hill, South Carolina
Air compressor health is critical for energy efficiency
Preventive maintenance, through regular inspections, servicing and scheduled part replacements, keeps systems reliable, energy-efficient and compliant with safety and quality standards.
Air compressors play a critical role in manufacturing, supplying reliable power for tools, machinery, conveyor systems and core processes that keep plant operations running efficiently.
In manufacturing, when an air compressor goes down or is not working at full capacity, production and the bottom line can take a hit. Just like a vehicle needs maintenance on a regular basis, air compres-
sors also need regular care to perform at their best. Most of the time, maintenance is only addressed after a compressor has already broken down, which leads to costly repairs, unplanned downtime and a loss in productivity.
Plant managers must take a proactive approach and consider preventive maintenance. By regularly inspecting, servicing and replacing parts before they break, compressors can run efficiently, last longer and avoid expensive disruptions in operations.
Why preventive maintenance matters for compressors
For most people, air compressors are not top of mind when it comes to everyday life, but they are often running for thousands of hours each year in manufacturing facilities. In production, even small issues with an air compressor, like a clogged filter or worn belt can turn into a major failure if left unchecked. That’s why preventive maintenance is critical to avoid disruptions.
Here are five ways maintenance can make a difference in a manufacturing facility:
1. Avoid costly downtime
When a compressor goes down suddenly, these unplanned interruptions can bring production to a standstill, which can impact deadlines, customer satisfaction and ultimately revenue. However, implementing a preventive maintenance schedule can catch potential problems early, so plant managers can schedule repairs during planned downtime instead of in the middle of a critical shift.
2. Extend equipment life span
Air compressors, like cars, require routine servicing to reduce wear and tear on important components, ensuring they last longer and perform consistently. This ensures a better return on investment and fewer expenses for replacements.
FIGURE 1: A preventive maintenance kit, as demonstrated by this service technician, is a critical component in air compressor health. Courtesy: Atlas Copco Compressors
3. Improve energy efficiency
A well-maintained compressor doesn’t have to work as hard to meet demand. With clean filters, proper lubrication and calibrated controls, energy consumption can be significantly reduced, in return, helping cut utility costs and reduce a plant’s environmental footprint.
4. Maintain air quality
In some industries like food and beverage, pharmaceuticals or electronics, air purity isn’t optional, it’s a requirement. Regular maintenance prevents contaminants like oil vapor, particulates and moisture from affecting products, equipment or compliance standards.
5. Support workplace safety
Failing components can pose safety risks to workers. Preventive maintenance ensures safety devices are working correctly and helps prevent hazardous failures.
When broken down, preventive maintenance is about more than fixing machines, it’s about protecting people, products and the bottom line.
Key benefits of preventive maintenance
Preventive maintenance isn’t just about having a checklist for making sure a system doesn’t break; it is also a way to keeping the air compressor system operating at peak performance. By keeping a regular service schedule, teams gain measurable advantages that impact efficiency, reliability and cost control. Benefits include:
Improved reliability: With routine inspections and timely part replacements, the chance of a sudden breakdown is significantly reduced. This means fewer production interruptions and more consistent output.
Cost savings: Catching even small issues early can prevent them from turning into costly repairs or even needing complete equipment replacement. Over time, this approach lowers the total cost of ownership.
Energy efficiency: A well-maintained compressor operates more efficiently, using less energy to produce the same amount of air. So, by replacing clogged filters, maintaining proper lubrication and calibrating controls ensure the system isn’t overworking and there is no unexpected surprise in energy bills.
Compliance and safety: For industries with strict regulatory requirements, preventive maintenance ensures that system stays compliant with safety and quality standards. It also helps prevent dangerous equipment failures that could put the team in danger.
Extended equipment life: The better the maintenance of a compressed air system, the longer it will last. Preventive maintenance will minimize wear and tear.
Common air compressor preventive maintenance tasks
When thinking about implementing a preventive maintenance program, it is important to know it works best when it’s consistent and thorough. While the exact steps will vary based on the compressor type, operating environment and workload, these are some of the core things that should be part of every plan:
Inspect belts, hoses and couplings: Check for cracks, fraying or wear that could lead to an unexpected failure. Make sure to replace any damaged components immediately to prevent downtime.
Change and clean filters: Air intake filters, oil filters and separator elements protect the system from contaminants. If a filter becomes clogged, it forces the compressor to work harder, wasting energy and shortening its life.
Lubricate and change oil: An oil-lubricated compressor requires regular oil changes to reduce friction, prevent overheating and protect moving parts. It is important to use the correct grade and quality recommended by the manufacturer. Using
2: Installing filter drains, as this service technician does, is a part of air compressor maintenance. Courtesy: Atlas Copco Compressors
Learningu
Objectives
• Understand the importance of preventive maintenance for air compressors and how it minimizes downtime, extends equipment life span, improves efficiency and ensures safety.
• Identify key preventive maintenance tasks and schedules, from daily checks to annual inspections and recognize how consistency in these activities prevents costly failures.
• Evaluate the role of professional service plans in supporting in-house efforts by providing OEM expertise, predictive monitoring, genuine parts and tailored maintenance strategies.
FIGURE
ENGINEERING SOLUTIONS
FIGURE 3: A service technician performs preventive maintenance to keep air compressors running optimally. Courtesy: Atlas Copco Compressors
‘Whether in-house or through a professional service plan, preventive maintenance should be looked at as more than just a checklist.’
oil that is incompatible with the equipment can be dangerous and costly.
Clean coolers and drains: Dirty coolers will reduce heat exchange efficiency leading to overheating and performance issues. Automatic drains should be inspected and cleaned regularly to ensure moisture is removed from the system.
Monitor system pressure and flow: It is important to check the pressure and flow values frequently to ensure the compressor is operating within optimal ranges. Sudden changes can be early signs of leaks, blockages or component wear.
Test safety devices: Regular checks of pressure relief valves, temperature switches and other safety components to make sure they are functioning correctly is important to protect both the equipment and team.
Calibrate controls and sensors: Making sure that a machine is properly calibrated ensures accurate readings for temperature, pressure and performance, confirming the compressor is operating efficiently and reliably.
Review monitoring data: If a compressor is equipped with a monitoring system, plant managers can review performance trends to catch early warning signs in real time and plan service before issues arise.
Recommended maintenance schedule
A successful preventive maintenance program
isn’t just about a list of tasks; it’s also about how often those tasks are completed. A consistent schedule ensures the air compressor operates at peak performance while minimizing the risk of unexpected issues.
While every facility’s needs are different, here’s a general guideline for routine care:
Daily
• Perform a quick visual inspection for leaks, unusual noises or vibrations.
• Check system pressure and temperature readings.
• Drain condensate from receivers and filters, if not using an automatic drain.
Weekly
• Inspect oil level and top off if needed (for oil-lubricated units).
• Clean or replace air intake filters if dirty.
• Check hoses, belts and couplings for wear or damage.
Monthly
• Inspect the safety relief valve and test operation.
• Check and tighten any loose bolts or fittings.
• Review monitoring system data for unusual performance trends.
Quarterly
• Change oil and oil filters (as recommended for the model; check manual).
• Replace separator elements if needed.
• Clean coolers and ensure proper airflow.
Annually
• Perform a full system inspection by a qualified technician.
• Calibrate controls, sensors and gauges.
• Test and document all safety devices.
• Review overall system performance and adjust maintenance plan as needed.
Following a structured schedule like this allows facilities to plan maintenance around production needs — and hopefully reduce unexpected and costly downtime — but it also ensures scheduled maintenance steps meet the annual budget, reducing any unexpected spending.
Service plans as a part of maintenance
Maintenance plans can be conducted in-house, but professional service plans are another option. Some organizations might benefit from the in-depth knowledge a professional OEM service technician can provide. These techs know the equipment and understand how to implement the appropriate maintenance procedures. Service plans are typically tailored to a plant’s needs.
Whether in-house or through a professional service plan, preventive maintenance should be looked at as more than just a checklist. It’s a mindset that protects a plant’s investment, keeps operations running efficiently and helps avoid costly surprises. By addressing small issues before they become major, the life of the air compressor is extended, energy efficiency is improved, product quality is safeguarded and workplace safety is ensured. PE
Jayme Leonard is a marketing communications professional at Atlas Copco Compressors.
After converting the gearbox of its corrugated box machine to LE’s Duolec® Industrial Gear Oil, a packaging company significantly reduced oil leakage and consumption, improved seal compatibility, and drastically reduced equipment noise.
FIGURE 4: A service technician performs a shock pulse measurement as part of a preventive maintenance plan. Courtesy: Atlas Copco Compressors
ENGINEERING SOLUTIONS
PREDICTIVE AND PREVENTIVE MAINTENANCE
Paul Haikal, Rockwell Automation, Cleveland
How to power sustainable operations with predictive maintenance
Maintenance is no longer considered a reactive tactic to address equipment failures. Predictive maintenance is a critical part of sustainable operations.
Every product ion line and supply chain tells a story through data, helping maintenance professionals evolve rapidly. Once viewed merely as a reactive cost center tied to equipment failures, maintenance has emerged as a strategic discipline. It currently drives operational excellence and positions organizations for longterm success. At the heart of this evolution is the integration of artificial intelligence (AI), cloudbased platforms, advanced asset monitoring and a growing ecosystem of digital capabilities.
Predictive maintenance versus preventive maintenance
• Understand predictive maintenance’s role in powering sustainable operations.
• Learn how cloud-based maintenance systems use generative artificial intelligence (AI) to improve operational sustainability.
• Establish how automation has streamlined the maintenance and repair process in industrial facilities.
Historically, preventive maintenance relied on predetermined schedules, often based on manufacturers’ recommendations or generic best practices. While this approach reduced the risk of catastrophic failures, it frequently resulted in inefficient resource allocation and unnecessary maintenance activities.
The landscape is shifting toward predictive and prescriptive maintenance, enabled by data-driven technologies and sophisticated algorithms. Modern cloud-based maintenance management systems leverage generative AI not just to anticipate when assets are likely to fail, but also to analyze several factors — operational data, historical
trends and environmental conditions — and provide prescriptive recommendations. These innovative systems forecast the probability of failure, suggest tailored corrective actions and schedule interventions with remarkable precision. Maintenance is carried out at the optimal moment, maximizing asset longevity and reducing both operational costs and downtime.
Harness real-time data for asset health
Critical to this transformation is the proliferation of embedded sensors throughout industrial environments. Motors, drives, pumps and other assets are now outfitted with devices that continuously monitor vibration, temperature, current and other vital metrics. As machinery begins to degrade, these sensors detect subtle shifts, flagging early signs of distress long before a complete breakdown occurs.
Advanced anomaly detection
engines process this vast stream of equipment data, identifying deviations from established performance baselines. Low-level asset condition monitoring provides granular insights, allowing maintenance teams to act proactively. This sensory information is fed into cloud-based management platforms, where it is contextualized and transformed into actionable intelligence.
Integrate anomaly detection with inventory management
Predictive maintenance systems extend far beyond merely forecasting failures. By integrating anomaly detection outputs with inventory management, organizations can ensure that the precise parts and materials are always available for upcoming repairs. Smart algorithms analyze usage patterns,
maintenance history and current inventory levels to optimize procurement processes.
The result is a significant reduction in production downtime, streamlined parts ordering and technicians who are empowered to focus on value-adding activities rather than scrambling for spare components.
Close the loop between monitoring and maintenance
Maintenance platforms automate much of the workflow that once demanded manual oversight.
Here’s how it works. When an anomaly is detected:
• A work order is automatically generated and routed within the maintenance management system.
• Inventory databases are checked in real time, with necessary parts reserved or ordered.
• Technician’s schedules are optimized according to availability, skillset and proximity to the affected asset.
• Prescriptive recommendations, drawn from both historical data and AI-driven insights, guide the repair or adjustment process.
FIGURE 1: Preventive maintenance is becoming a bigger priority for many manufacturers, and data is a crucial piece of those initiatives. Courtesy: Adobe Stock
‘The landscape is shifting toward predictive and prescriptive maintenance, enabled by data-driven technologies and sophisticated algorithms.’
This high degree of automation ensures that maintenance actions are timely, coordinated and efficient. Production disruptions are minimized, while asset uptime and overall equipment effectiveness reach new heights.
Scale predictive maintenance across the enterprise
Manufacturers often operate complex environments containing both legacy equipment and state-of-the-art machinery. Asset-agnostic models, meaning those capable of learning from diverse machine types and conditions, enable organizations to standardize maintenance practices and gain enhanced visibility across the enterprise. Whether monitoring high-speed packaging lines, remote pumping stations or intricate assembly robots, these platforms scale effortlessly, delivering consistent, reliable results throughout global operations.
ENGINEERING SOLUTIONS
‘The journey toward fully predictive and autonomous maintenance is well underway, marked by significant progress and tangible results.’
Integration with broader enterprise platforms such as production management, enterprise resource planning and supply chain systems further amplifies the impact of predictive maintenance strategies. Asset data flows freely across organizational silos, enabling smarter decision making, optimized production schedules and continuous improvement.
Empower the workforce
The success of advanced maintenance strategies depends not only on technological prowess but also on an empowered industrial workforce. Augmented reality (AR) and digital twin technologies are reshaping how operators and technicians interact with equipment. Through immersive visualizations, workers can view real-time asset health, receive step-by-step troubleshooting support and access remote expertise with unprecedented ease.
Context-aware recommendations delivered directly to mobile devices or AR headsets enhance productivity and safety, bridging knowledge gaps and reducing the likelihood of errors. By making actionable insights accessible at the point of need, organizations foster a culture of continuous learning and operational mastery.
Support sustainability and ESG goals
Predictive maintenance is increasingly recognized as a driver of environmental, social and governance (ESG) objectives. By ensuring equipment operates at peak efficiency, organizations minimize energy consumption, reduce waste and lower greenhouse gas emissions.
Maintenance platforms facilitate the tracking and reporting of sustainability metrics, aligning operational practices with responsible business strategies and regulatory requirements.
Condition monitoring and AI-powered maintenance management
The future of maintenance hinges on the seamless interaction between condition-monitoring tools and intelligent management platforms. Embedded sensors capture a constant stream of operational data, while anomaly detectors flag any deviations that might indicate impending issues. This information is rapidly transmitted to cloudbased systems, where generative AI analyzes, interprets and orchestrates timely interventions.
The collaboration between asset monitoring and AI-powered maintenance management creates a truly predictive, resilient and efficient environment. Maintenance becomes not only a function of risk mitigation but an engine of value creation. This allows organizations to extend asset life cycles, enhance productivity and stay ahead in a competitive market.
The future of predictive maintenance with generative AI
As organizations look toward the future, a range of advanced capabilities are poised to transform maintenance even further. Generative AI will enable dynamic, condition-based planning that adapts in real time to changing circumstances. Digital twins will simulate entire production lines, optimizing schedules, resource allocation and operational performance. Autonomous agents will learn from ongoing operations, offering real-time recommendations and driving continuous improvement.
These technologies are already proving their worth in predicting equipment failures and identifying preventive measures. The journey toward fully predictive and autonomous maintenance is well underway, marked by significant progress and tangible results.
In the modern industrial landscape, the scope of maintenance extends beyond simple repair and upkeep. It encompasses resilience, operational efficiency and sustainability — integrating AI, data-driven insights and strategic alignment with broader business goals. Though traditionally viewed as a cost center, maintenance today is a crucial enabler of value, driving operational success and competitive advantage.
Organizations that embrace integrated tools, data resources and advanced workflows within their maintenance strategy are positioned to unlock both immediate and long-term benefits. The ongoing evolution of maintenance practices presents a golden opportunity: to move from reactive responses to proactive, value-oriented processes and to transform maintenance into a powerful catalyst for growth and excellence in the world of manufacturing. PE
Paul Haikal is a commercial portfolio manager for Rockwell Automation’s visualization software business.
*Based on current (July 2025) efficiency data published in accordance with the Compressed Air and Gas Institute (CAGI) third-party verification program.
ENGINEERING SOLUTIONS
MECHANICAL AND ELECTRICAL
Chris Morris, TEADIT, Pasadena, Texas; and Angelica Pajkovic, TEADIT, Toronto
Know these eight design factors for optimal gasket performance
To achieve leak-free performance, understand what factors help improve gasket performance.
In industrial environments, gasketed joint reliability often makes the difference between efficient operations and unplanned downtime.
Whether in a refinery, chemical plant, power generation station or pulp and paper mill, sealing product performance plays a crucial role in the site’s overall reliability.
Learningu
Objectives
• Understand the critical role of gasket design and material selection in ensuring joint reliability, safety and emissions compliance across industrial applications.
• Identify key factors that influence sealing performance, including temperature resistance, pressure containment, chemical compatibility, vibration and environmental exposure.
• Apply best practices for gasket installation and maintenance to prevent common failure modes, improve system integrity and extend the service life of sealing systems.
Gaskets are often given little consideration within the overall scope of maintenance operations. Everyone knows they need to have them, but the nuances of different types and materials and the pros and cons of each, are not well understood in many cases. Though gaskets are often thought of as simple and at times interchangeable components of a piping system, they are specifically and carefully engineered to maintain system pressure and contain process media while withstanding mechanical, thermal and chemical attack. Their success or failure directly impacts plant safety, emissions performance, product purity and mechanical integrity.
It is essential to recognize that gasket performance is not determined solely by the product itself, but by the interaction of the sealing material, the flange, the bolts, the operating conditions and the installation practices. When sealing considerations are properly evaluated and managed, the entire system benefits from improved performance and reliability.
Gasket considerations during the design phase
Sealing failures rarely occur due to poor-quality gaskets. Most leaks that result in containment loss
stem from insufficient design, incorrect installation or the selection of unsuitable materials. Therefore, it is important to consider these eight design factors for optimal gasket performance.
1. Temperature resistance and thermal cycling
Gaskets must accommodate both steady-state operating temperatures and, when present, thermal and pressure cycles. In applications such as heat exchangers or reactors, process temperature changes can cause significant system movement, resulting in the loss of bolt preload and gasket stress.
Flexible graphite, for example, is a popular choice for applications running at higher temperatures (above 500°F). These gaskets are also highly compressible, allowing them to conform to flange surface imperfections.
However, flexible graphite sheet gasket materials generally exhibit limited recovery, meaning that once they are compressed, they do not rebound. Gasket recovery is critical in cycling applications and therefore is a primary consideration for these services. The use of graphite for facings and fillers in semi-metallic gaskets like spiral wounds or corrugated metal gaskets take advantage of the temperature resistance of the material, while at the same time adding robustness that leads to better recovery.
2. Pressure containment
A properly selected gasket will typically withstand the system's internal pressure while maintaining an effective seal over time. High-pressure systems often benefit from spiral-wound gaskets, which combine alternating wraps of metal winding with a soft filler material (often graphite).
Spiral-wound gaskets come in a variety of styles, with the most common being the industry standard pipe flange version that includes both an outer guide ring that centers the winding on the flange and an inner ring to resist inward radial buckling.
‘Engineers must evaluate the storage of gaskets and materials when selecting a sealing solution.’
The added benefit of the inner ring is that it stiffens the gasket preventing the windings from being easily over-compressed and increasing the gasket’s overall tightness and recovery.
Additionally, changes within the last decade to the American Society of Mechanical Engineers (ASME) B16.20: Metallic Gaskets for Pipe Flanges standard that governs spiral wound manufacturing have resulted in improved winding density which leads to better overall performance. Since the 2017 revisions, B16.20 spiral-wound gaskets have been designed to meet sealing performance thresholds.
3. Chemical compatibility
Gasket material must be chemically compatible with the process media it is exposed to. Recognized for their ability to withstand harsh chemicals, polytetrafluoroethylene (PTFE)-based materials are an ideal choice for applications that use or are exposed to acids, caustics, solvents and aggressive hydrocarbons.
The chemical structure of the PTFE polymer allows the material to resist many of the common mechanisms that lead to chemically induced mechanical degradation of the material. Expanded PTFE (ePTFE) is highly conformable to irregular flange surfaces like those found in lined vessels and is a valuable option for applications where ultra-clean service or regulatory compliance is required. Blue, fawn and off-white restructured PTFE gaskets incorporate fillers like glass microspheres, silica and barium sulfate to reduce gasket creep, enabling their use in demanding chemical processing environments without sacrificing mechanical stability.
4. Vibration and mechanical movement
Sealing systems subjected to vibration, pipe stress or rotating equipment must be designed for joint flexibility. Materials with high recovery
characteristics, damping and resistance to extrusion help maintain sealing performance under mechanical load variation. Some of these materials can conform to out-of-flat flanges while maintaining adequate sealing stress, reducing the likelihood of gasket failure.
5. Environmental exposure
External factors, including ultraviolet exposure, weathering, aging and thermal shock, may influence material longevity. Engineers must evaluate the storage of gaskets and materials, as well as the installation environment in tandem with process conditions when selecting a sealing solution.
While a popular choice for many general service applications, elastomeric gaskets or gaskets that contain elastomeric binders are highly susceptible to these factors and care should be taken to ensure that these gaskets are suitable for installation. Signs of brittleness or cracking are clear indicators that the gasket is unfit for service.
Graphite and PTFE, on the other hand, perform reliably in a wide range of ambient environments with little to no impact on the gasket’s mechanical properties. However, advancements in coatings for rubber-based gasket materials, such as nonstick or anti-oxidation layers, have improved removal during maintenance and extended service life in harsh environments.
FIGURE 1: Depiction of gasket material before being cut into gasket. Courtesy: TEADIT
ENGINEERING SOLUTIONS
MECHANICAL AND ELECTRICAL
FIGURE 2: Example of gaskets made from a variety of polytetrafluoroethylene (PTFE)based materials.
Courtesy: TEADIT
6. Material selection across sealing types
The material properties, such as chemical resistance, compressibility, thermal stability and creep relaxation, must align with the application's operational environment to maintain sealing integrity and extend service life. The range of materials available today enables precise tailoring of gasket properties to application demands.
• Elastomers and rubber-based fiber sheets: Cost-effective for low-pressure systems, available in a variety of combinations.
• Virgin skived PTFE: Unfilled, clean and stable across a broad chemical range; suitable for sanitary, food-grade and pharmaceutical low temperature services.
7. Application-specific engineering
Every sealing application is unique. Steam systems require materials with thermal stability. Chemical applications demand robust chemical resistance. Sanitary systems must comply with NSF/ANSI 61, FDA 21 CFR or USP Class VI standards.
Specialized manufacturers address this diversity by offering both standardized and custom-engineered sealing materials. Innovations such as specialized PTFE gaskets for glass-lined equipment and flange-isolation gasket kits for cathodic protection have enabled more precise solutions for challenging or niche applications.
8. Joint design and tolerances
‘
Design engineers should model joint stress and relaxation behavior under load and thermal conditions.’
• Restructured PTFE: This is filled PTFE with improved strength and reduced creep relaxation, ideal for dynamic thermal and pressure conditions.
• ePTFE: Compressible, chemically resistant and ideal for irregular flange surfaces.
• Flexible graphite: High-temperature performance with excellent stress relaxation and thermal conductivity.
• Metallic and semi-metallic gaskets: Spiral wound, kammprofile, corrugated metal and ring-type joint gaskets for high-pressure, highload systems.
Gasket selection must be coordinated with flange geometry, surface finish and assembly practices. Flanges must be flat, parallel and free from damage. The fasteners generate the clamping forces that load the gasket and create a seal and are therefore a critical component in flange joint reliability. Bolt loading, performed with a calibrated tool, must be uniform and within calculated torque values.
Design engineers should model joint stress and relaxation behavior under load and thermal conditions to ensure long-term sealing integrity. Innovative joint modeling software and digital training tools have contributed to more consistent field performance and easier training of maintenance teams.
Installation discipline and failure prevention for gaskets
A gasket is designed to form a static seal by occupying the tiny irregularities between flange
faces and distributing compressive load evenly across its surface. However, the correct installation, in addition to suitable material and design selection, is crucial for maintaining that seal over time.
Proper installation ensures that the gasket deforms as intended, maintains sufficient stress under operational pressure and temperature and prevents the loss of containment. This level of performance demands a precise approach that includes material compatibility, appropriate torque sequencing and a strong understanding of system behavior.
Sealing failures often result from conditions that are preventable. Several contributing factors include:
• Low bolt load that fails to develop adequate sealing stress.
• Use of bolts with insufficient strength to maintain the load under service conditions.
• Gasket stress loss due to relaxation.
• Gasket relaxation, creep or cold flow, reducing gasket stress over time.
• Over-compression of the gasket, causing crushing or material extrusion.
• Loosening of bolts caused by system vibration.
• Gasket displacement from pressure surges such as water hammer.
• Uneven flange loading due to misalignment or improper torque sequencing.
• Chemical degradation when materials are not compatible with the process fluid.
• Mistakes during installation, such as reusing a gasket, incorrect torque or poor flange surface preparation.
These failure modes can result in leakage, compromised system integrity, safety hazards or costly downtime. Preventing them requires discipline and adherence to engineering best practices:
‘Precision, attention to detail and a strong safety culture are essential in every flange assembly.’
• Use the correct gasket material for the process conditions.
• Select bolts of appropriate grade and lubricate properly.
• Thoroughly clean and inspect flange surfaces for damage or warping.
• Apply bolt torque using a calibrated tool based on procedures or engineering analysis per ASME PCC-1: Pressure Boundary Bolted Flange Joint Assembly and retorque where applicable. Semi-metallic gaskets, like spiral wound gaskets and kammprofile gaskets, often do not require retorque.
• Train maintenance personnel and emphasize documentation and consistency.
Effective sealing depends as much on field execution as it does on material science. Precision, attention to detail and a strong safety culture are essential in every flange assembly.
Treat gasket sealing as a strategic component
Sealing products are not commodity items; they are engineered components that must be designed to meet application requirements. Gaskets and sealing systems serve as the last line of defense in maintaining containment, process integrity and operational continuity.
It is important to have a comprehensive understanding of the application requirements and conditions, as well as a thorough knowledge of the best available technologies when selecting a sealing solution for the connection of any piping system. PE
Chris Morris is a Sales Engineer for TEADIT. Angelica Pajkovic is a Client Specialist at TEADIT.
Insightsu
Gasket insights
uThis article highlights how gasket reliability is central to plant safety, emissions control and operational efficiency, emphasizing that sealing success depends on material selection, joint design and disciplined installation practices.
u By treating gaskets as engineered components rather than commodities, facilities can significantly reduce failures, improve uptime and extend system reliability.
ENGINEERING SOLUTIONS
ENERGY EFFICIENCY AND MANAGEMENT
Amit Patel and Eugenio F. da Silva, Emerson, Florham Park, New Jersey
How to achieve plant sustainability goals through energy monitoring
Real-time energy and compressed air monitoring gives manufacturers visibility and control to drive environmental initiatives.
Meeting corporate sustainability initiatives is a high priority around the world. According to a 2024 sustainability report, 85% of global executives say their companies have increased sustainability investments in the past year. Half of the companies included in the report have already begun to implement technology solutions as part of their strategies to reach environmental goals, while another 42% are planning to do this within the next two years.
In addition to their own scope one emissions, these companies are also focused on minimizing scope two and scope three emissions throughout their supply chains. Nearly half (47%) of companies require suppliers and business partners to meet specific sustainability criteria. Having successful sustainability initiatives can give original equipment manufacturers and suppliers a competitive advantage.
Realizing energy savings opportunities
Pneumatic systems can be found in almost every industry, but they are especially prevalent in factory automation, automotive, food and beverage, life sciences, semiconductor and utilities applications. On average, 20% to 30% of a facility’s total energy consumption goes toward generating compressed air. But once it is generated, most manufacturers have no idea how it's used or how much of it goes to waste. This lack of visibility makes it challenging to optimize and control use, which in turn makes it challenging to meet sustainability goals.
It may surprise most manufacturers to know that, between leakage and machine suboptimization, around 30% or more of the compressed air a plant generates goes to waste. Machines often consume compressed air even when idle. This inefficient use of air is called standby loss.
• Explore how to achieve plant sustainability goals through energy monitoring.
• Understand how real-time energy and compressed air monitoring gives manufacturers the visibility and control to drive environmental initiatives.
• Assess the different solutions available to track energy consumption and efficiency.
To reach sustainability goals, it is critical that manufacturers have visibility into how their operations use energy as well as the ability to control this usage. This includes the electricity that equipment uses and the energy used to generate other resources, such as compressed air.
Real-time compressed air and energy monitoring makes it possible for manufacturers to gain a greater understanding of how assets, lines and plants use energy. With this knowledge, their teams can better address waste and optimize use. By achieving this level of control, companies can more effectively and accurately track and reach sustainability goals.
Leakage is another significant form of waste. Leaks can develop in pneumatic systems over time and compressed air can escape. With leaks, energy waste is not the only expense. On average, 76% of businesses still manually test for compressed air leaks across their facility. Manually checking for leaks can cost an average of $46,000 per machine due to service equipment and training investments and leaks can go undetected and grow between the periodic checks.
At the same time, manufacturers also have a great opportunity to address standby power, the power consumed by idle equipment. Machine tools are energy intensive, making up about 53% of elec-
tricity consumption by end use. Although they run only 15% to 40% of the time, they still consume high power when idle. Optimizing machine usage can cut energy use by 10% to 25%.
Additionally, identifying and reducing peak loads can directly reduce the net capacity surcharge. Reducing the baseload by optimizing the highest consumers can significantly reduce overall energy consumption.
Manufacturers that can identify and address compressed air waste and standby power have significant opportunities to improve energy efficiency, optimize energy use, reduce related carbon emissions and meet net zero goals. Real-time compressed air and energy monitoring makes it possible.
Assessing ways to track energy consumption, efficiency
With so many companies either implementing or planning to implement technology solutions as part of their sustainability strategies, it's important to understand which solutions are available and what their limitations are.
Some utility monitoring solutions are developed in-house based on programmable logic control or supervisory control and data acquisition platforms. While they can be customized, these do it yourself solutions often require programming and may have limited data analytics and visualizations. They may also be difficult to integrate with existing industrial internet of things technology.
Cloud-based applications are another option, typically integrated with enterprise systems through software-as-a-service models. However, they can be expensive to implement, which makes it difficult for companies to start small, prove success and scale up. It may also be difficult to justify the recurring cost of software as a business grows.
Energy consulting firms can provide manufacturers with audits and advice, but they may lack the expertise to implement projects that address findings. This leaves manufacturers on their own to find the right technology for their needs.
Utility metering vendors offer energy monitoring devices with proprietary software applications, which can lock vendors into specific hardware and prevent integration of third-party devices.
Overall, these products, services and audits lack the comprehensive visibility needed to track energy use, the automation and control to optimize con-
sumption and the scalability to prove success and invest over time. What’s more, personnel may experience data overload and lack the expertise to maximize the value of these solutions. The sheer volume of data from machines can be difficult to analyze and is often siloed.
In comparison, there is now a scalable, plug-and-play integrated solution that monitors compressed air and energy use in a comprehensive way in real time. Its software applications have an intuitive interface and dashboards that effectively provide visual insights and alerts that are easy to understand without specific technical expertise.
Optimizing compressed air and electricity use
‘Reducing the baseload by optimizing the highest consumers can significantly reduce overall energy consumption.’
By tracking both compressed air and electricity use at the same time, manufacturers can gain a greater understanding of how their facilities consume energy and increase the number of ways they can identify and address inefficiencies. And by using a solution that is easy to install, use and scale, companies can get started quickly and maximize the value of their investment.
FIGURE 1: Real-time compressed air and energy monitoring makes it possible for manufacturers to gain a greater understanding of how assets, lines and plants use energy. Courtesy: Emerson
ENGINEERING SOLUTIONS
How monitoring enables energy reduction and reduces costs
Total Compressed Air Consumption
Total Energy Consumption
By monitoring total compressed air and electrical energy usage while collecting accurate data from air flow sensors and energy meters, customers can accurately calculate consumption, costs and related CO2 emissions.
Compressed Air Consumption per Machine
By setting a baseline and thresholds, users can visualize in detail how specific machines are consuming compressed air and use this to benchmark consumption across different production lines.
Identify Potential Leaks And Losses
By analyzing detailed patterns of a machine's compressed air consumption in different time periods, such as idle, between shifts and weekends, users can pinpoint waste and potential leaks.
Energy Consumption per Machine
By analyzing energy consumption per asset or production line, users can pinpoint inefficiencies, such as specific machines or related processes that consume more energy than they should.
Peak Demand Reduction
By analyzing detailed energy usage information, users can schedule machines for off-peak hours or change production processes to use energy more efficiently.
CO2 Impact and Cost of Energy Consumed
By inputting local energy and utility costs into the applications and the associated CO2 factor (kg/kWh), the total kilograms of CO2 emitted due to electricity and/or compressed air consumption can be calculated.
energy costs and carbon
energy
The preprogrammed and pre-engineered cabinet solution includes smart airflow sensors and two applications, one for compressed air monitoring and the other for energy monitoring, on the same edge hardware.
Both software applications provide advanced analytics from an individual machine level up to a complete line or facility. Energy dashboards show
‘As companies realize energy benefits and cost savings, they also see productivity benefits and cost savings.’
asset-specific energy consumption, power demand, voltage- and frequency-related charts, associated energy costs and carbon dioxide (CO2) emissions. Compressed air dashboards identify leaks and display key performance indicators and metrics such as air flow, pressure, energy costs and CO2 emissions.
Easy access to these key performance indicators and metrics gives sustainability teams a unified
view to track and drive initiatives. And using these dashboards, operators can uncover opportunities for improving energy efficiency, such as machines that waste energy while idle or early-stage leaks. The dashboards can also reveal when simultaneous operations during peak hours lead to spikes in energy consumption, allowing operators to strategically adjust shifts and enhance overall energy management.
For instance, one facility used the solution and identified several inactive systems running during the third shift shutdown. This allowed the site to reduce consumption during third shift production. In the first six months, the initiative resulted in about $125,000 in savings.
When a plant improves energy efficiency, operational efficiency naturally follows. As companies realize energy benefits and cost savings, they also see productivity benefits and cost savings. For example, it can improve overall equipment effectiveness values and lower per-unit production costs, too.
The scalability of the solution makes it possible for manufacturers to begin with one machine, production line or asset — like a proof of concept — and then expand from that point. This approach
FIGURE 2: Designed to help manufacturers cut
emissions by up to 30%, the Energy Manager solution transforms
challenges into opportunities. Courtesy: Emerson
allows them to maximize their initial investment while building valuable expertise along the way. Manufacturers can scale up when they are ready, adding more sensors. As they scale, the value and return on investment (ROI) increases as well.
Manufactures who are currently using the compressed air monitoring solution are seeing a 30% to 50% reduction in compressed air consumption and typically realizing ROI in less than two years.
Making good energy strategy good business strategy
To better meet sustainability goals, it's important that the monitoring technology a company uses is easy to access and use. And, to meet other business goals, it's important that solutions are quick and easy to install and provide fast ROI.
Whether companies are taking the first step of their sustainability journey or starting the next leg, partnering with a digital transformation expert with a comprehensive portfolio makes it possible to go farther.
An expert partner can help manufacturers maximize the value of their sustainability investments. They can identify and prioritize opportunities by examining the largest energy-consuming assets and pinpointing areas of high utility usage where immediate efficiency improvements can be made for cost savings. They can also provide a future-proof platform that is scalable and adapts with evolving needs and lower total cost of ownership.
Real-time compressed air and energy monitoring makes it possible for manufacturers to get a clear picture of waste and take action to optimize energy use. In this way, addressing compressed air and energy consumption at the same time offers a significant opportunity for manufacturers to meet sustainability goals — and gain a competitive advantage. PE
Amit Patel is Director of Portfolio Commercialization, Intelligent Automation at Emerson. Eugenio F. da Silva Neto is Product Manager, Intelligent Automation at Emerson.
Insightsu
Energy insights
uManufacturers are increasingly using technology to monitor compressed air and electricity in real time, helping them reduce waste and improve energy efficiency as part of broader sustainability strategies.
u By optimizing how facilities consume energy, companies can cut costs, lower carbon emissions and gain a competitive advantage while meeting sustainability goals.
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Brit Thielemann, Hitachi Global Air Power, Michigan City, Indiana
Boosting compressed air efficiency: Practical ways to maximize a system
There are practical strategies to boost compressed air efficiency — through air audits, smart operating practices and proactive maintenance.
Compressed air has often been called the fourth utility, after electricity, water and natural gas. According to the U.S. Department of Energy, electricity accounts for more than 75% of the total life cycle costs of an individual compressor. That means the bulk of what facilities spend on compressed air is tied to energy — not equipment or maintenance.
Yet in many manufacturing operations, compressed air can also be one of the least efficient utilities. Although most modern rotary screw air compressors are engineered to be highly efficient, common issues like leaks, poor system design, improper maintenance and inefficient operation often waste significant amounts of energy. In some facilities, more than half of the compressed air produced never gets used.
The good news? There are proven ways to boost compressed air efficiency — improving both system performance and the bottom line. From air audits and proactive maintenance to optimizing compressor turndown and reclaiming waste heat, there are many opportunities to reduce costs while also extending the life of the compressed air equipment.
Boosting compressor efficiency with an air audit
The foundation of any efficiency-boosting effort is understanding how the system is performing. This is where an air audit can help inform efficiency opportunities.
An air audit is essentially a health checkup for a compressed air system, measuring how much air is being generated, how it’s being used and where it may be wasted. There are two ways of auditing a system: supply-side and demand-side. Supply-side audits look at how a compressor, dryer and filters are performing — this includes compressor sizing.
FIGURE 1: Compressor placement is vital to machine efficiency. Select a room that is clean, easily accessible for maintenance and repairs and temperature controlled. Courtesy: Hitachi Global Air Power
Conversely, demand-side examines how air is distributed throughout the manufacturing operation. This can often uncover hidden problems such as leaks, misapplied air tools or inappropriate uses of compressed air, like blowing off debris instead of using brushes or vacuums.
Regular audits are one of the best ways to uncover savings, often revealing complex problems hidden to the untrained eye. Audit-based action plans can cut maintenance costs by as much as 60% and reduce electrical costs by up to 50%.
The best time to audit a system is whenever a facility adds, removes or replaces equipment or when manufacturing patterns change, like adding a second shift. Even without these major changes, it’s still important to schedule an air audit every three to five years.
Operate smarter: compressor turndown and efficiency
Small operational changes can make a big difference when it comes to efficiency. Oversized compressors waste energy, while undersized machines can’t keep up with demand. Operating too far outside the compressor’s optimum efficiency range can also backfire.
Rotary screw compressors are designed with an ideal speed range for maximum efficiency and performance. If the compressor operates too slowly or too quickly, efficiency drops –– and in some cases, equipment life may be compromised. Consequences can include increased energy usage, hot air backflow and overheating risks and premature coating wear on rotors in oil free rotary screw compressors.
To address these challenges, some facilities find the best solution is a combination of compressors — a base-load machine running steadily at high efficiency, paired with a smaller trim compressor that handles variable demand. This prevents larger machines from inefficiently cycling on and off.
Variable speed drive compressors are widely used as primary compressors where less air is needed or as a secondary compressor as mentioned above because they can adjust output to match plant demand.
However, not all turndown ranges are created equal. Always look beyond original equipment manufacturer marketing claims and check Compressed Air and Gas Institute data sheets when evaluating compressor efficiency, paying particular attention to specific power. Specific power indicates
how much power must be used for each cubic foot per minute (cfm, measured in kilowatts or kW per 100 cfm). The higher the specific power, the more caution should be taken, because a plant will need more kilowatts and pay more money to obtain the same amount of air.
Other smarter operating tactics include turning off compressors when idle. Much like “phantom energy” from electronics left plugged in at home, idle compressors can still draw power even when not in use. Shutting them down during evenings, weekends or long breaks prevents waste.
Finally, compressor room temperature also plays a role in efficiency. Compressors perform best in well-ventilated spaces with minimal dust and stable temperatures. Conversely, poor room conditions force compressors to work harder and reduce efficiency.
Don’t overlook pipes, valves and fittings
Leaks in pipes, valves and fittings are among the most persistent efficiency killers. Studies suggest that up to a third of compressed air is lost to leaks, forcing compressors to run longer and harder to maintain pressure. Even a seemingly minor leak
FIGURE 2: Regular and preventive maintenance will keep an air compressor running efficiently and reliably. Courtesy: Hitachi Global Air Power
‘Small operational changes can make a big difference when it comes to efficiency.’
u
Objectives
• Learn how to recapture heat and water compressed air byproducts can help reduce utility costs.
• Understand the ways in which audits, proactive maintenance and other strategies can boost efficiency.
• Determine the best strategies to reduce energy usage from air compressors.
ENGINEERING SOLUTIONS
can translate to thousands of dollars annually in wasted energy.
The following are estimated additional costs for operating a compressor with air leaks. The calculations are done at $0.0771 kW hours (kWh) operating 8,000 hours/year.
• Compressor using 200 cfm at 325,000 kWh/year: $27,139/year
• Compressor using 300 cfm at 528,000 kWh/year: $40,709/year
• Compressor using 400 cfm at 704,000 kWh/year: $54,278/year
*Bob Vavra of Plant Engineering
One of the best ways to manage leaks is to check the system annually. Ultrasonic detectors are great at locating smaller leaks that are inaudible to the human ear. Once a leak is found, don’t walk away too quickly — tagging and prioritizing the leak will aid repair efforts and ensure all leaks are addressed appropriately.
Beyond pesky leaks, piping layout and size can impact efficiency. Discharge piping should never be reduced below the compressor outlet size. Upsizing piping is often beneficial because it reduces pressure losses. Piping should also be set up to mini-
mize sharp 90-degree elbow turns with sweeping bends or radius fittings used wherever possible.
Piping connections and materials are also critical; tying into the top of a main header prevents piping from acting like a drip leg and forcing condensation back toward the compressor. And choosing the right material for an application should be carefully considered. Aluminum piping is lightweight, noncorrosive and easy to install. Galvanized steel and copper may also be used, though each has trade-offs. Older iron pipes should be replaced, as corrosion buildup from moisture restricts airflow over time.
And do not forget about valves. A three-valve bypass around filters and dryers allows equipment to be serviced without shutting down the entire system. Installing auxiliary ball valves in strategic locations also makes it easier to connect rental compressors during planned or emergency maintenance.
No compressor efficiency article is complete without mentioning the importance of proper maintenance. Compressed air systems are generally only as good as the care they receive. Proactive and predictive maintenance not only prevents downtime but ensures a compressor runs at peak efficiency. The basics include:
• Filter replacement: Inlet air filters prevent dirt and dust from entering the compressor. A clogged filter forces the compressor to work harder, increasing energy costs. Replace quarterly or as recommended by the manufacturer.
• Oil sampling and fluid replacement: For lubricated rotary screw air compressors, testing oil quality helps spot potential issues early. Fluids should typically be replaced annually — or sooner in harsh environments.
• Drain management: Moisture is an unavoidable byproduct of compressed air. Installing reliable drains (such as zero-loss drains) ensures water is removed without wasting air. Neglected drains often stick open, leading to costly leaks.
FIGURE 3: Piping material, size and configuration all play important roles in compressed air efficiency. Courtesy: Hitachi Global Air Power
Reclaiming waste energy for added efficiency
Even the most efficient compressor converts most of its input energy into heat — up to 90% to 95% of the electrical energy consumed by a compressor ends up as heat. Heat vented to the atmosphere by a compressor can be used for facility heating, preheating boiler feedwater or providing process heat for cleaning, drying and other applications.
Similarly, moisture extracted from compressed air can often be reclaimed as gray water for nonpotable uses, such as irrigation or certain washdown processes. While this approach is not suitable for every plant, water recovery can be particularly beneficial in areas with high water costs or restrictions.
Recapturing and using waste heat and/or water adds efficiency by reducing utility bills and potentially improving sustainability metrics.
Measuring and tracking savings
Implementing efficiency measures isn’t enough. It’s important to collect and analyze the results of
these efforts. Monitoring platforms and energy management tools provide a 360-degree view of system performance, helping plants quantify energy savings. Regularly reviewing performance data also enables continuous improvement. As operating conditions and facilities need change, system optimization should evolve too.
Compressed air is a critical utility in many plants — and it’s one of the most manageable. By combining audits, proactive maintenance, smart operating practices and recovery systems, a facility can cut energy costs, extend equipment life, reduce downtime and improve sustainability. The key is recognizing that efficiency is not a single project but an ongoing process — one that pays dividends in performance, reliability and longterm savings. PE
Brit Thielemann is the director of application engineering and customer experience with Hitachi Global Air Power.
Air compressor insights
uRegular audits uncover leaks, misuses and other inefficiencies.
uProactive maintenance including filters, drains, leak repairs and daily inspections keep systems efficient and reliable.
uSmart operation strategies, such as matching compressor supply to demand, avoiding excessive cycling and shutting down idle units help to save energy.
PREDICTIVE AND PREVENTIVE MAINTENANCE
Scott Smith, Motion Repair and Services, Eugene, Oregon
Ways to modernize lubrication systems in rotating equipment
Effective lubrication is required to properly maintain the reliability and longevity of rotating equipment in demanding industrial environments. Today’s technologies help optimize lubrication performance while minimizing downtime and maintenance costs.
LLearningu
Objectives
• Understand key considerations when upgrading lubrication systems in heavy-duty industrial applications including flowmeter selection, system controls and feedback and alarms.
• Learn the benefits of integrating advanced monitoring technologies to refine lubrication accuracy, thereby extending machinery life and reducing downtime.
• Realize the importance of cross-functional collaboration, considering all viewpoints to design a system upgrade that fully supports optimal machine operation.
ubrication systems can benefit any facility by extending machinery life and reducing operating costs. However, heavy-duty operations, such as steel, pulp and paper and mining, often have a high number of lubrication points, which can be difficult to manage.
Furthermore, many facilities still depend on legacy equipment that was not designed for modern add-ons like automated lubrication and predictive maintenance technology. Rotating equipment is especially vulnerable to these challenges, increasing the risk of unplanned downtime and higher costs. Bearings, gears, rotors and other rotating components all require the right amount of lubrication at the right time.
Considering an upgrade can be daunting. Beyond the cost factors, decisions must be made regarding controllability, electronic control interfacing, system sensors and feedback, visual and electronic event verification, data logging, component placement and downtime required to install and commission — the list is long.
Lubrication flowmeter selection
In any oil lubrication system for rotating equipment, controlling the flow rate to the lubrication
point is a fundamental requirement. Flow rate control can be achieved through various means, from a simple inline adjustable orifice to a complex bank of meters equipped with electronic monitoring, feedback and alarms (see Figure 1).
Changes in oil temperature, affecting viscosity, must also be considered. If the system viscosity is constantly changing due to temperature variation, selecting a flowmeter device that compensates for viscosity changes will help maintain accurate, metered flow to the lubrication point.
Variable-area flowmeters that are simply designed and commonly used in many of today’s systems have a typical accuracy range of about 1.6% to 5% with changes in temperature and viscosity. If your lubrication requirement demands tighter accuracy, consider a different type of device.
Oval gear flowmeters and turbine designs are commonly used to maintain tighter flow accuracy over a broad range of temperature and oil viscosity changes. These devices can deliver a very tight accuracy over oil viscosity changes ranging from 30 to 1,000 centistokes.
Cost is relative to accuracy; the higher the accuracy over a range of viscosity changes, the higher the initial investment. Key questions are: What flow range does your system require and what level of per-point accuracy is needed to provide efficient lubrication and maximize life for the rotating component?
System controls
Plant engineers have many options of advanced system controls to incorporate into a new system or system upgrade. The days of relying solely on buttons, manual adjustment and visual indication are far behind.
By combining flow banks and software, we can provide a user interface for the centralized system. These systems allow users to monitor and control
Monitor series enclosure is shown newly installed in a paper mill. It is one of a network placed throughout the mill to precisely monitor and control lubricant flow, optimizing bearing performance and life.
Courtesy: Motion
the metering system in real time — displaying flow rates, adjusting flow rate alarm limits and collecting flow rate, oil and alarm trends in the system.
Interface controls range from simple human-machine interface controllers and programmable logic controller-based systems to more complex industrial solutions that can integrate with factory systems, such as supervisory control and data acquisition, for enhanced oversight.
Controllability via Bluetooth mobile devices is also a growing trend with many lubrication system manufacturers.
Feedback and alarms for lubrication
The demand for real-time flow feedback and system alarms continues to increase. The ability to monitor any given flow rate to a lube point provides great reliability in a system. Coupled with flow alarming, a machine operator, maintenance technician or reliability leader can be instantly notified of a system problem that requires attention. Real-time feedback is a valuable tool in avoiding insufficient lubrication, which can cause heat
CASE STUDY: How to overhaul a bearing lubrication system upgrade
A PAPER MILL REQUIRED an updated bearing lubrication system with precision monitoring.
A paper mill faced a critical challenge: its large paper machine’s bearing lubrication system was outdated and unreliable. Without the advantage of precision monitoring, inefficiencies disrupted production and increased downtime risk. In collaboration with the mill and a key bearing supplier, the Motion team designed and installed a comprehensive lubrication system upgrade. For a seamless implementation, experts planned a phased approach.
The yearlong project was meticulously designed to minimize disruption to the mill’s operations and was executed in phases during scheduled machine shutdowns. Phase 1 involved replacing 13 flowmeter stations with state-ofthe-art monitoring meters, enabling controlled oil lubrication for the paper machine rolls’ rotating spherical bearings.
This critical phase involved detailed planning, careful removal of outdated equipment (see Figure 2), precise installation, plumbing modifications and thorough system commissioning (see Figure 3). Future phases will focus on replacing the remaining flowmeter stations, ensuring a complete system overhaul.
Flowmeter accuracy over changes in temperature and viscosity are integral in the upgrade to provide consistent flow levels to each bearing lubrication point (see Figure 4). The monitor systems measure and feed individual oil flows directly to each point. Though oil temperature and viscosity can change, monitors provide accurate results. They calculate the flow rate by measuring the turbine rotation time and considering the user-entered
2 AND 3: Old-school, variable area flowmeters (left) were replaced with modern SKF Flowline Monitoring stations (right). The new enclosures consist of multiple 10-point assemblies stacked inside a stainless-steel enclosure. A two-bank or 20-point enclosure is shown right. Courtesy: Motion
FIGURE 1: This four-bank, 40-point SKF Flowline
FIGURES
ENGINEERING SOLUTIONS
FIGURE 4: A three-point injector block manifold mounted on the paper machine for continued, controlled lubrication monitored by the stations. Courtesy: Motion
viscosity grade. The onboard temperature sensor measures the oil temperature for improved precision.
The paper mill’s bearing lubrication system is delivering tangible benefits. The meters precisely monitor and control lubricant flow, optimizing bearing performance and extending service life. This translates to enhanced lubrication reliability and significantly reduced risk of unexpected breakdowns and costly production stoppages.
Additionally, the modernized system ensures optimal bearing lubrication delivery, minimizing waste and boosting overall equipment efficiency.
The monitoring stations were installed with new stainless-steel tubing connections over the course of various plant outages during the year. Thirteen monitor stations were installed to handle the total number of oil lubrication points in the system.
The project's success is due to the seamless collaboration between key players, especially during the crucial first phase. One team brought invaluable on-site expertise, project management and technical execution, while another supplied its advanced monitoring meter technology. The teams worked closely together on the system design, with the mill’s success as the shared goal.
FIGURE 5: A dual-line grease pumping and control system delivers precise amounts of grease in a paper mill. Courtesy: Motion
Phase 2 involves the installation of a dual-line grease system (see Figure 5), which is close to completion and being implemented during sequential plant outages.
The system upgrades, both oil and grease, provide an accurate and efficient solution that can be monitored by the plant control system and detect problems early before any harm comes to the rolling devices. System maintenance can be better planned during scheduled outages, increasing machine uptime.
‘Operators, engineers and reliability and maintenance teams each have different needs in a lubrication system. ’
from increased friction, and wear, which can lead to component damage.
These types of devices provide real-time, continuous monitoring and alerts for lubrication system issues, helping to prevent component/equipment failure, reduce downtime and ensure optimal system performance. Notifying operators or other plant personnel before a problem becomes severe allows for timed and planned maintenance.
Importance of collaboration
Whether you choose oil or grease or complex or simple systems, there is a lubrication solution to fit your demanding industrial applications. Collaboration among all machine stakeholders is vital. Operators, engineers and reliability and maintenance teams each have different needs in a lubrication system.
All viewpoints must be considered to design a system upgrade that fully supports optimal machine operation. Discuss these points with your plant engineers and consult a qualified third party to explore all possible solutions to optimize your lubrication processes and keep your operation running smoothly. PE
Scott Smith is Division Manager - West Shops for Motion Repair and Services.
Insightsu
Lubrication insights
uConsider these upgrade considerations for lubrication systems: flowmeter selection, system controls and feedback and alarms.
uManaging all lubrication points within a heavy-duty manufacturing facility can require precision monitoring.
ENGINEERING SOLUTIONS
PLANT AUTOMATION
Austin Levin, PE, ACS Inc., Verona, Wisconsin
How robots maximize workforce efficiency and automation
Robots can significantly boost manufacturing efficiency by automating demanding tasks, optimizing workforce deployment and future-proofing operations with modular, centralized control systems.
In a manufacturing environment defined by persistent labor shortages and the demand for increased output, plant managers are continuously seeking new ways to boost efficiency. While the promise of robotics has been a part of this conversation for years, modern robotic solutions, particularly when paired with advanced control systems, are no longer just a luxury — they are a critical tool for operational success. By automating strenuous, repetitive tasks, companies can not only improve throughput but also enhance safety and cultivate a more flexible, skilled workforce.
The case for robotic palletizing
A corrugated box manufacturer recently faced a common industry challenge: a physically demanding task at the end of a collator line that required workers to palletize stacks of flat-pack boxes. The job was so physically taxing that employees had to be rotated in 90-minute shifts, leading to recruitment and retention difficulties. The company needed an automated solution that would free up labor for other tasks while ensuring the utmost safety for its employees.
The solution was a custom-engineered robotic palletizer. The system, designed to handle seven different box sizes, was built around a robot with a custom end effector. This “hand” of the robot was crucial; it was specifically designed with programmable pressure and depth settings to lift and stack cardboard without causing dents. To handle thin slip sheets between layers, the end effector was also equipped with programmable suction cups, demonstrating the level of customization required for a truly efficient system.
The results of this implementation were immediate and impactful. The company was able to reduce the labor needs on the line from three workers to two. The robotic palletizer took over the physically intensive role, allowing the company to reassign
FIGURE 1: To ensure operator safety, the ACS team designed physical and programmable mechanisms, with the robot operating in a three-sided fenced area that runs only when gates are securely closed. Courtesy: ACS Inc.
‘This dual-layer approach is essential for protecting workers and creating a safe, collaborative environment.’
its workforce more strategically and improve overall efficiency. The system's success was so evident that the client purchased a second robot for another line, confirming the clear return on investment.
The role of intelligent control systems
While the physical robot does the work, the brain behind its efficiency is the robotic control system (RCS). Unlike traditional setups where each robot operates with its own separate controller, an RCS centralizes control of multiple robots and all peripheral devices into a single, unified system. This approach offers several advantages that directly contribute to long-term efficiency:
• Simplified management: An RCS makes it possible for plant controls engineers, who are fluent in programmable logic controllers, to manage, adapt and troubleshoot the entire system. This reduces reliance on niche robot programmers and makes robot integration more accessible.
• Space optimization: Centralized control eliminates the need for separate control cabinets and programming space around each robot, enabling tighter layouts and saving valuable floor space. This is a measurable financial benefit that directly impacts a plant's bottom line.
• Modularity and flexibility: RCS architecture is inherently modular and “future-proof.” When manufacturing needs change, new components can be added or reconfigured with minimal disruption to the existing control logic. For the palletizer, this meant the system could be easily programmed to handle new product profiles simply by adding dimensions and stacking configurations into the controller, which can be done in under 30 minutes.
Integrated safety with robots
Any discussion of industrial robots must prioritize safety. The successful palletizer implementation included a robust combination of physical and programmable safety mechanisms. The robot's work area was secured with a physical fence with proximity switches and door locks. On the fourth side, a
light curtain provided a protective barrier that would automatically shut down the system if breached. Perhaps most critically, the robot was programmed with an internal geofence that enforces spatial limits on its movement. This dual-layer approach — combining physical barriers with software constraints — is essential for protecting workers and creating a safe, collaborative environment.
Robots: a path to scalable manufacturing
Ultimately, using robots to improve efficiency is not about simply replacing a worker. It's about strategically deploying automation to solve critical operational problems, enhance worker safety and create a scalable, flexible manufacturing process. By leveraging turnkey solutions and the power of intelligent control systems, manufacturers can simplify complex processes, optimize their workforces and remain competitive in a rapidly evolving market. PE
Austin Levin, PE, is Lead Automation Engineer at ACS Inc. He develops and implements automated systems to streamline processes and improve efficiency for clients.
Learningu
Objectives
• Analyze the multifaceted benefits of robotic automation beyond just labor replacement, including improved safety, increased production consistency and enhanced workforce flexibility.
• Evaluate the strategic importance of a robotic control system in achieving long-term efficiency, scalability and simplified management for plant operations.
• Identify key features of a successful robotic implementation, such as custom-engineered end effectors, integrated safety mechanisms (like geofences and light curtains) and user-friendly, modular programming.
FIGURE 2: Custom robot for efficient box stacking. Courtesy: ACS Inc.
ENGINEERING SOLUTIONS
PLANT AUTOMATION
Dan Furrow, Wesco, Pittsburgh
Robots offer efficiency, flexibility, safety on the plant floor
Since 2011, industrial robot technology has rapidly advanced, offering manufacturers a clear way to improve efficiency and profitability.
When you think about robots on the plant floor, you may likely still picture the large, expensive orange and yellow robotic arms used by auto manufacturers. While there is still a place for such machines, the industry has evolved quite a bit since those robots were first introduced in the 1960s.
But they have never evolved as quickly as they have over the past 14 years. According to a report from the International Federation of Robotics, robotics usage across industrial and manufacturing settings has recently reached record highs. As of 2024, more than 4 million robots were installed in factories across the globe, a 10% increase from the previous year.
Here’s how robots can impact efficiency, flexibility and safety in today’s manufacturing environment.
Efficiency is an advantage
Over the past 10 years, robots have become faster, more efficient, more user-friendly and available in a variety of form factors, many of which can be easily customized to a specific user. They can integrate with other advanced technologies like automation software, sensors and artificial intelligence, creating a more cohesive factory that can proactively address issues, mitigate production concerns and alleviate staffing deficiencies.
This level of operational intelligence and innovation is exciting but understanding where and how robots can bring an immediate impact is often the first step to deployment — and the ability to justify a broader rollout. As such, a common initial objective is to significantly increase throughput by extending the active hours of the facility and supplementing human workers to make them more efficient.
• Understand why you can’t talk about robotics and efficiency improvements without also talking about flexibility and safety.
• Learn what it means to have greater flexibility on the plant floor.
• See how robotics can create a broader safety net for less obvious risks and concerns.
That unprecedented level of adoption and engagement has driven manufacturers of all sizes to more closely consider how they can incorporate robotics in their operations. Identifying opportunities to glean new efficiencies is often the top priority, given the challenges that exist across the manufacturing landscape — most notably thin margins, skilled labor shortages and supply chain uncertainties. Robots have an obvious role to play when it comes to improving efficiency, but you cannot talk about the role of robotics in manufacturing without also talking about the impact they have on plant flexibility and worker safety.
For example, using a collaborative robot or “cobot,” can empower human workers to complete more work during a single shift. This capability can allow manufacturers to deliver better margins, enhance overall output and improve profitability.
Product quality and reducing defects also impacts the ability to enhance overall plant efficiency. Robots also can be implemented to help improve product quality by ensuring precise and repeatable manufacturing processes, crucial elements for producing high-quality parts consistently.
For example, welding is a precise function that requires significant attention to detail. By deploying robots designed specifically for welders, manufac-
turers can use easy-to-use robotic arms with joystick controls to create the exact same lines, circles and weaves and do so with the same level of speed control that is required to deliver the final product. These robots also cater to the needs of welders by eliminating the need for programming experience. The applications are incredibly user-friendly and can be up and running with precise, accurate control in less than 2 hours.
As an added benefit, the cost to implement robots has come down significantly. While still an investment, incorporating robots is typically cheaper today than it was several years ago.
Flexibility via robots: an understated byproduct
Robots can also deliver one thing that has often been elusive to manufacturers — flexibility. Instead of deploying dedicated machinery for each specific piece of the manufacturing process — often requiring a costly investment — many robots are now highly customizable.
For example, a food processing plant may use robots to fill bags of different sizes and weights. Those products can then be packaged and shipped in appropriately sized boxes, eliminating the need
1: Robots can offload repetitive tasks such as moving can bins across the plant floor, which not only frees up workers up to focus on more critical tasks, but helps to minimize their risk of ergonomic injuries
as well.
‘Instead of deploying dedicated machinery for each specific piece of the manufacturing process, many robots are now highly customizable.’
for multiple machines. This customization and flexibility allow the manufacturer to switch between different packaging requirements easily and deliver the finished product no matter the specifications. These robots can be programmed at the outset to weigh, label and package the product and can also be easily modified or updated with a few clicks of a button.
This also can be valuable in a pharmaceutical environment. In the past, perhaps the medication was processed on a conveyer belt, flowed downstream to quality control and then to packaging. Each step was carefully choreographed, each moving at the same pace and if something went wrong the entire process could be held up. With advanced robotics, the products can be taken in groups to their specific stations and come back together at the end, guided around the facility by a robot.
FIGURE
Courtesy: Wesco
ENGINEERING SOLUTIONS
Robots are not one size fits all. Smaller robots like the one pictured here can be a more affordable option for companies looking to enhance their operations and improve productivity. Courtesy: Wesco
There is no more waiting for specific parts or challenges upstream to be addressed, and no more halting production until one process is fixed. Instead, the manufacturing process can be flexible and yet maintain operations with the necessary quality controls.
Using robots to enhance safety
One of the most common examples of robots impacting safety on the plant floor involves minimizing human exposure to hazardous areas. Robots can enter dangerous sections to perform critical yet high-risk tasks such as taking temperature readings in extreme heat and cold or limiting human exposure to hazardous fumes. This is incredibly valuable, as safety is a key component to a profitable operation.
Deploying robots also offloads the repetitive tasks that can lead to ergonomic injuries or pose other safety risks. These hazards often aren’t quite as obvious, but repetitive stress injuries for these workers can have a big impact.
While ergonomic injuries may seem minor at first, their impact on joints, tendons, nerves and muscles builds up over an extended period of time.
‘Many manufacturers are now looking for smaller-scale robots that take up less floor space, offer greater flexibility and provide a greater range of benefits.’
Research shows that these injuries can have a lasting effect. According to research from the Bureau of Labor and Statistics, nearly 33% of “days-awayfrom-work” cases are due to ergonomics-related injuries and worker compensation claims tied to this issue cost U.S. employers more than $20 billion per year. By minimizing ergonomic injuries and preventing workers from going on autopilot, robots can contribute to a safer working environment, even as they deliver the efficiency gains manufacturers are after.
Industrial-sized robots specific to only one task are phasing out of the plant floor. Instead, many manufacturers are now looking for smaller-scale robots that take up less floor space, offer greater flexibility and provide a greater range of benefits. While efficiency may be the jumping-off point, robotics inherently bring even more value to the plant floor through their ability to provide more flexibility and impact broader safety concerns. And, as overall costs have come down, robots can often be much more affordable today. If you haven’t looked at how robots can enhance your operations — or if you haven’t done so recently — now might be the time to start. PE
Dan Furrow is Senior Vice President, Global Accounts and International Markets at Wesco.
Insightsu
Robot insights
uRobots help manufacturing plants improve efficiency and profitability while also achieving two key byproducts in the process — more manufacturing flexibility and broader safety improvements.
u A collaborative robot, or “cobot,” can help human workers complete more work safely and effectively.
Are autonomous mobile robots right for your plant?
Autonomous mobile robots (AMRs) might not be right in your facility, and it’s smart to consider options.
Over the past decade, autonomous mobile robots (AMRs) have revolutionized industrial processes by providing increased efficiency and reducing labor costs. Despite their benefits and their stunning rise from niche to mainstream, mobile robots are not without their limitations. This is especially true when it comes to the expensive, complex and often clunky sensor packages used to provide safety functions like obstacle detection.
Typical robot sensor packages
AMRs rely on a combination of sensors for safety and navigation. The most common sensor packages include light detection and ranging (LiDAR) and cameras, both of which have their own strengths and weaknesses.
LiDAR sensors are widely used for their ability to create detailed 2D maps of the environment. They are excellent at detecting objects in a 2D plane but struggle with overhangs, protrusions and transparent objects. LiDAR also has limited field of view, which narrows its ability to provide safety across all scenarios and can lead to blind spots and missed obstacles. For example, it might detect the arms of a human working on the ground, but it won’t see that there’s a head connected to those arms.
Most of the safety issues around AMRs these days happen because LiDAR has failed to detect an overhanging or underhanging object. And this can lead to some dangerous and unexpected scenarios.
For example, if an AMR’s LiDAR fails to detect a
FIGURE 1: ADAR enables 3D 360-degree obstacle detection around autonomous mobile robots (AMRs) at a lower cost than other sensor packages. Courtesy: Sonair
ADAR LiDAR
pallet on the ground, it could end up pushing that pallet around creating all sorts of potential risk to people and property.
2D LiDAR is typically mounted on the AMR at an 8-inch height. That means it won’t be able to detect feet, so you must add the distance of a foot to your safety. Moreover, there's a chance that someone could step over 8 inches toward a robot and the robot won’t detect anything before the foot steps down into the zone again.
Similarly, multiple safety scenarios have occurred where a forklift has been left in the wrong location or with its forks raised, leading to AMRs and their goods becoming impaled on the misplaced vehicle.
It’s fair to say that today’s approaches to obstacle detection on AMRs are a little too 2D.
Handling robotic limitations
3D cameras are frequently used on AMRs to provide a workaround for those limitations and to enhance safety performance. While these expensive cameras provide rich visual information and often supplement LiDAR data, they are not safety certified. Moreover, cameras can be affected by reflections and varying lighting conditions, leading to unreliable data.
AMRs may also incorporate proximity sensors as part of their overall sensor systems. Like the parking sensors used on cars these are ultrasonic sensors, but that type of ultrasonic sensor can only provide one-dimensional distance information — not enough to close the safety gaps in today’s AMR sensor packages.
All these expensive and complex sensors — including the workarounds — end up contributing massively to the cost of AMRs, pushing prices up for end users and AMR builders. And they need regular maintenance too from wiping dust from the lens every day to dealing with the latest software updates. From the AMR builder’s perspective, integrating complex sensors accounts for a big chunk of their time. And yet, most AMRs today tend to take a similar approach — incorporating a clunky combination of 2D and 3D LiDAR and 3D cameras.
If AMR builders appear locked into a 2D LiDAR-based approach, it’s because LiDAR has achieved safety certification, more or less obliging companies to embrace the technology despite its limitations.
Sensor technology advances
A different approach to sensing and obstacle detection is set to change how AMR builders approach safety and obstacle detection, with the promise of enhanced, 360-degree safety and obstacle detection at a lower price point than current sensor packages.
Dubbed acoustic detection and ranging (ADAR), the sensor uses beam-forming — a processing technique widely deployed in sonar, radar and medical ultrasound imaging — to enable in-air ultrasonic applications. The technology has omnidirectional depth perception, enabling it to “hear” its surroundings by analyzing information from airborne sound waves.
FIGURE 2: 2D safety LiDAR are typically mounted on AMRs at a height of around 8 inches and won’t detect objects 4 inches above the floor, objects hanging from the roof or items sticking out from walls or shelves. These limitations present safety risks in dynamic environments.
Courtesy: Sonair
Objectives Learningu
• Understand the primary limitations and pain points of current sensor packages used in autonomous mobile robots (AMRs) for safety functions.
• Identify how acoustic detection and ranging (ADAR) addresses the shortcomings of traditional AMR sensor systems by offering enhanced 3D safety coverage that can detect previously missed obstacles.
ENGINEERING SOLUTIONS
‘Robots that share spaces with humans will always need a combination of sensors to ensure safe human-robot interactions. ’
Insights
Robot insights
uThe article highlights that despite their benefits, autonomous mobile robots (AMRs) face significant challenges with current expensive, complex and 2D sensor packages, particularly 2D LiDAR and 3D cameras.
uThis can result in safety gaps and blind spots and introduces a 3D ultrasonic sensor.
u Don’t settle for the bare minimum. Choose a gas supplier that checks all your boxes
This 3D ultrasonic sensor has potentially massive implications for AMR design and safety. A single ADAR sensor can provide a 180x180-degree field of view and a 16.4-foot range for safety functions. Unlike traditional 2D LiDAR sensors, ADAR-based sensors can detect overhangs, protrusions and low-lying obstacles effectively. ADAR doesn’t struggle with transparent surfaces. In effect, the sensor establishes a 3D safety shield for obstacle detection around any mobile robot.
Despite enhancing safety by being more capable than LiDAR when it comes to obstacle detection, ADAR is cheaper than both LiDAR and camera-based obstacle detection. This provides AMR makers with an opportunity to lower costs for end users.
Robots that share spaces with humans will always need a combination of sensors to ensure safe human-robot interactions across multiple applications and environments. None of this is to claim that ADAR is “one sensor for every application.”
However, for AMR builders, ADAR is a powerful addition to their toolkit; a cost-effective, small form factor, easy-to-integrate alternative to complex camera and LiDAR setups. It also provides AMR manufacturers with an opportunity to stay competitive in a rapidly evolving AMR market by providing enhanced safety at a lower price point.
For end users, it means greater peace of mind when sharing busy facilities with fleets of AMRs, knowing that the robots are kitted out with safety sensors that provide full 360-degree, 3D coverage — and that the robot trundling by with $500,000 of product on board is not going to impale itself on a forklift anytime soon. PE
Mathias Madsen is a Robotics Engineering at Sonair.
Before selecting an industrial gas supplier, make sure you partner with one that will be there every step of the way... For over 80 years companies have depended on Air Products for turnkey industrial gas solutions. We provide essential industrial gases, related equipment and applications expertise to customers in dozens of industries including, refining and chemicals, metals, electronics, manufacturing, food and beverage, and more.
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Discover the Power of CITGO Lubricants: Online Resources for Professionals
Stay informed in the world of lubrication with our expert-led training workshops and webinars designed for industry professionals and customers. Presented by seasoned CITGO ® Lubricants Technology Experts and marketing specialists, these specialized sessions offer valuable insights into the latest CITGO, Mystik ® and Clarion® Lubricants product lines, technologies and programs. As a valued industry professional, you have unrestricted access to industry-focused webinars designed to keep you and your team abreast of the latest trends in lubricants. Whether you’re looking to deepen your technical knowledge or explore new solutions, our webinars provide the information you need – right at your fingertips.
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When an opportunity for being better or the best at what we do is available, why wouldn’t we take it?
As Engineers, Technicians etc., we should and, need to know what we are doing. Having a better understanding of our role is something that we can accumulate as we perform our jobs, but sometimes things come along that are ‘out of the norm’, just different or more complex than we can educate ourselves on, or perhaps related to a subject you may have only briefly covered during your formal education.
On the job training is only as good as those we are learning from, sometimes we need to seek additional help especially with much of the newer technologies we see today. While we could read books, manuals and these days even watch videos on the subject they often lack the ‘hurdle’ component, that’s the bit where we need additional guidance when something just didn’t make sense.
Training from an expert not only walks us through the process but also enables us to ask questions that may arise while doing so; the ‘hurdle’ effectively need never exist.
While finding time to take advantage of these opportunities may be a challenge, we should take them when we can. Companies such as DEWESoft offer opportunities both in-house and a variety of locations around the country to provide that training from beginner to expert in a variety of different subjects, consider the advantage and ultimate time saving as well as possibly creating local experts so the future on-the-job trainings you give will truly cover the needs of the role.
“ Training from an expert not only walks us through the process but also enables us to ask questions that may arise while doing so; the ‘hurdle’ effectively need never exist. ”
Training session with Dave Gallop, Business Development Training Manager — Dewesoft
Scan, Issue, Solve: Corteva’s Smart Inventory System Cuts Automation Downtime
CHALLENGE: Inefficient tracking of inventory and automation stoppages using spreadsheets, leading to slow part issuanace and unintegrated downtime data.
SOLUTION: Purchasing MAPCON and customized inventory features
RESULT: Reduced automation downtime due to faster part issuing and a unified platform for analyzing all maintenance events, enabling better insights.
Corteva Agriscience provides farmers with crop protection (insecticides, fungicides, etc.) as well as higher-performing seeds.
The plant was experiencing difficulty managing critical maintenance information across disparate spreadsheets. Tracking inventory for automation repairs was cumbersome, causing delays in obtaining necessary parts and prolonging equipment downtime. Simultaneously, a separate log of automation stoppages lacked integration with repair and preventative maintenance (PM) records.
They invested in MAPCON with a custom inventory scanning window accessible via an always-on PC workstation. With a Bluetooth scanner, technicians could quickly scan and issue parts needed for automation repairs. An error-tracking window was created for the automation team. They could swiftly log automation stoppages, record immediate repairs, and generate follow-up work requests.
The implementation of these custom solutions yielded positive results. The instant part issuance capability contributed to a reduction in automation downtime. By integrating the logging of automation stoppages directly into MAPCON alongside repair and PM data, the plant gained a unified platform for tracking and analyzing all maintenance-related events.
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At SEW-EURODRIVE, we engineer the highest quality drive automation solutions. What truly sets us apart is our unwavering commitment to customer support, long after the sale. We go above and beyond to ensure your business stays on the move with exceptional service at every turn. Upgrade everything.
From planned projects to last-minute needs, The Home Depot delivers on your schedule—same day, next day or any day you need to keep the job moving. When and Where You Need It.
