You can also improve what works well

"Some plant managers think that once something works well, improvements are not necessary. This approach is understandable, especially when dealing with complex processes where it has taken a long time to get them running properly. And once a line or machine is running reliably, there seems little point in looking for areas for improvement. Yet plant managers will have to let go of that thought," states Patricia Torres, Industry Marketing Manager Food & Commodities Solutions at OMRON Industrial Automation Europe.

Manufacturers have now begun their journey toward climate neutrality. In doing so, a passive attitude toward factory automation is out of the question. "Reducing CO2 emissions is necessary to achieve the net zero goals for 2050. That requires optimizing and adapting existing plants and processes - even if they work perfectly," Torres said. She discusses some of the ways OMRON supports companies on their path to decarbonization.

Moving fossil-free

"AMRs (autonomous mobile robots) are gaining in importance. They run on batteries, making them a fossil-free alternative to forklifts for transporting boxes and pallets. Moreover, they are intelligent enough to return to the charging station when needed. They can also replace conventional linear conveyors. Unlike traditional AGVs, no facility modifications such as floor magnets or navigation beacons are required."

Cobot palletizer

"With the rise of e-commerce and the trend toward High Mix Low Volume production, the popularity of mixed pallets - with multiple products on one pallet - is increasing. The challenge here is optimizing the various patterns to make better use of space during transport and storage. Ultimately, fewer pallets means lower CO2 emissions per unit. This requires complex programming. OMRON therefore developed a new cobot palletizer to load mixed pallets more efficiently. The palletizer is based on the modular machine controller of the NX1 series with a specialized function block and integrated intelligent vison in the robot arm."

Energy-saving variable speed drives

Third, Torres mentions energy-saving variable speed drives. "Everything that moves in a plant is powered by energy, whether it's a motor, pump, drive, fan or compressor. Compressed air is one of the biggest energy wasters. Measures such as using smaller compressors for lower requirements, installing electronic speed variators, installing heat recovery systems and limiting pressure loss can make compressors more energy efficient. For pumps, optimizing yield control and motor power helps increase energy efficiency." The importance of variable speed drives should also not be overlooked. "Replacing old ones with newer ones can make a huge difference to the energy efficiency of equipment. The technology of variable speed drives has evolved greatly in recent times."

Smart sensors

Reducing energy consumption is necessary to meet net-zero targets. "In addition to workplace changes, smart strategies that use Internet of Things (IoT) and Artificial Intelligence (AI) models play an important role. They help analyze data and identify potential efficiencies. This is why OMRON has developed the i-BELT service. This converts real-time data from production lines into meaningful solutions for eliminating inefficiencies and implementing improvements." Torres cites an example. "In a clean room environment, i-BELT was used to monitor air and operating situations 24 hours a day. It was found that there were hours when production and quality were not adversely affected by turning off the air conditioning. This can save a lot of energy."

Sensors

"One of the challenges for companies is to collect reliable data. This requires sensors. Old production lines are not equipped with sensors - or at least not sensors that are correctly placed and accurate enough for smart monitoring. Therefore, effective use of sensors is a prerequisite for any data management platform."

Some quick improvements

"While there are certain manufacturing environments where small changes can yield big savings, achieving net-zero often requires fundamental changes in other, more complex areas, such as production data collection and analysis and shop floor movement of goods. Innovative technologies will play an important role in this. But it is a myth that only new manufacturing facilities can be energy efficient. There are all kinds of ways to make existing plants and production lines more sustainable," Torres concludes.