The Hidden Environmental Impact of Automation Projects

At Actemium Avanceon, many of the projects we execute may not immediately appear to be environmental initiatives, but they are critical to reducing our carbon footprint and contributing to the global effort against climate change. Our role in optimizing energy efficiency and improving operations inherently helps reduce emissions, conserve resources and promote sustainability.

Let’s explore some of the impactful projects we’ve worked on that make a real difference to the environment.

Match processes to motor energy levels  

One example is changing the approach to batching projects by using the control philosophy of mixing to the right energy level. This approach focuses on optimizing the mixing of materials to achieve specific viscosities by monitoring the mixer motor’s energy profile. While this may seem like a straightforward process improvement, the impact on energy consumption is significant. By ensuring that energy is used efficiently during the mixing process, we reduce excess energy expenditure that would otherwise be wasted. This not only improves operational efficiency by reducing batch times, it also lowers the carbon footprint of our clients' operations by ensuring the mixer only runs as long as necessary to achieve the right consistency profile. 

Water reuse

Another powerful example of sustainability is our work with retort hot water reuse. In food processing plants, for example, hot water used for cooling cans can be repurposed as preheat or refill water for heat exchangers elsewhere in the facility. This not only reduces the need for additional energy to heat water but also maximizes the utility of existing resources. It's an elegant solution to reduce water and energy consumption, further decreasing the overall environmental impact of the facility's operations.

PID loop analytics

A key component of our approach to sustainability is the use of PID (proportional-integral-derivative) loop analytics in process control. PID is a predictive control method that fine-tunes system performance, ensuring optimal efficiency. In industrial applications, PID loops adjust processes like flow, temperature and pressure in real-time to maintain ideal conditions. By leveraging PID analytics along with historical perspectives to improve loop performance, we can precisely manage operational control, preventing overcompensation and reducing waste. This leads to lower energy consumption, improved system efficiency and a smaller carbon footprint for our clients' operations.

Sustainability through practicality

As I mentioned earlier, these projects may not directly appear to be environmental projects, but each plays a part in reducing the overall environmental impact of our clients’ operations. Whether it’s through energy optimization, resource conservation or waste reduction, every step counts.

Our approach focuses on making sustainability accessible and impactful, showing that environmental responsibility doesn’t require grand gestures or major investments. By incorporating efficiency into everyday operations, we are collectively making a difference.

As we move forward, we continue to seek innovative ways to incorporate environmental sustainability into every facet of our work. From energy savings to process optimization, every project we undertake contributes to our broader goal of reducing emissions and minimizing environmental impact.

Matt Ruth is president at Actemium Avanceon LLC, a certified member of the Control System Integrators Association (CSIA). For more information about Avanceon, visit its profile on the CSIA Industrial Automation Exchange.