Sustainable industry starts with efficiency

The transformation of industry towards greater sustainability and climate protection is one of the greatest challenges of our time. However, the first and perhaps most important step on this path is surprisingly simple: using energy more efficiently and thus reducing both energy consumption and costs in a targeted manner. This is where electrification and digitalization come into play, two technological drivers that reinforce each other and together unleash enormous energy efficiency potential. The electrification of industrial processes reduces the use of fossil fuels and significantly cuts greenhouse gas emissions. At the same time, digital solutions enable precise control and monitoring of energy consumption. Intelligent sensor technology, data-based analyses and automated processes ensure that energy is used exactly where it is needed and in the optimum quantity.

The complete conversion of systems and machines to an electrical energy supply is a complex and resource-intensive project that requires careful planning, technical expertise and investment. Sustainable innovations in the electrification and automation of industrial processes can already be implemented in small and manageable steps. Targeted individual measures can also bring about significant increases in efficiency and energy savings. For example, the electrification of certain sub-processes - such as the replacement of conventional drives with highly efficient electric motors or the use of electrical process heat - can make a measurable contribution to reducing energy consumption. In addition, the modernization of control and regulation technology helps to make processes more demand-oriented and resource-efficient.

The first step is to create transparency

The digital networking of generators, consumers and storage systems forms the basis for the efficient and flexible use of renewable energies in the electricity supply. By using intelligent systems, all energy flows are recorded and controlled in real time. This creates the necessary transparency about when, where and to what extent electricity is generated and consumed. This precise information makes it possible to use the naturally volatile energy generated in line with demand and distribute it with maximum efficiency, thereby exploiting the full potential of renewable sources. These principles can also be applied to industrial production facilities. Data transparency makes it possible to identify inefficient processes or unexpected energy losses. For example, it can be determined that the numerous electric drives of a complex packaging machine are not working as efficiently as expected in practice, despite their nominally high efficiency. This may be due to insufficient utilization, unfavourably set acceleration profiles or the lack of an intermediate circuit for recovering braking energy. Without granular, systematic recording and analysis of energy data, a lot of optimization potential remains untapped. Only those who specifically measure and evaluate can intervene, adapt processes and sustainably increase energy efficiency.

Recognizing and exploiting the potential of IoT

In the industrial environment, the Internet of Things (IoT) enables a more sustainable use of resources by creating transparency and highlighting optimization potential. For example, in order to produce flexibly and in line with demand in small batch sizes, systems are needed that can react quickly to orders and exchange data between software and hardware in real time. This means that only the minimum amount of resources and energy is consumed that is actually needed. Digital sustainability measures also help to increase reliability. This is particularly important in sectors such as the food industry, where perishable goods are processed. IoT-based systems allow maintenance to be planned in a predictive and targeted manner thanks to precise condition data. In addition, the use of augmented reality enables quick access to all important information on system parts, which makes fault localization much more efficient.

Digital technologies increase the efficiency of systems in two ways. They enable demand-driven and low-loss energy use, which also allows flexible adaptation to price fluctuations on the energy market. By shifting energy-intensive processes to times of low electricity prices, significant savings can be achieved. At the same time, they support employees and increase efficiency, as maintenance work can be carried out in a targeted and time-saving manner. In this context, however, it is increasingly important not to focus on short-term economic efficiency, but to recognize the benefits of sustainable corporate management holistically and make targeted use of them: After all, in addition to significant productivity gains and the positive impact on a company's own_{carbon footprint}, ecological sustainability also strengthens its reputation. This is a factor that is becoming increasingly important in terms of securing skilled workers, customer interests and access to attractive financing.

Ensuring the competitiveness of production

Electrification is a decisive factor for decarbonization and, in combination with modern automation technology, the most efficient way to secure and expand the competitiveness of the manufacturing industry. However, this requires an intelligent and flexible approach that makes full use of the technical possibilities and allows processes to be adapted to the dynamic conditions of the market. Only when efficiency is consistently increased in all areas will electrification and digitalization take full effect. The good news is that the technologies required for this have long been available.

Schneider Electric offers a comprehensive portfolio of industry-specific solutions to implement greater industrial electrification, automation and sustainability in all stages of the value chain, from planning to operation, intelligently, economically and sustainably.

Schneider Electric, http://www.se.com