Meaningful connections: connectivity challenges in Australia's process automation landscape

Connectivity is the most significant barrier to operational efficiency in Australia’s rapidly evolving processing and manufacturing landscape. However, it’s not the concept of connectivity that is the limiting factor, but the myriad of available protocols and their various abilities.

Food and beverage, mining, and oil and gas are just some industries that require modern technologies to handle complex operations. The benefits that modern connectivity present are extremely powerful and there are extraordinary opportunities in all areas of business, from the factory floor to the ERP department. The challenge for industry professionals lies in the integration and optimisation of these tools to increase output and quality, while reducing risks and costs.

The growing complexity of industrial networks

Traditional hardwired signals such as 4–20 mA still hold a commanding position across all industries, and these devices will remain relevant for many years thanks to their cost effectiveness and simplicity. But to financially and sustainably maximise processes, these devices need to be smarter.

Connectivity is no longer simply a matter of plugging devices into a network. An intricate web of protocols, platforms and standards must work harmoniously to deliver real-time data for informed decision-making.

The adoption of industrial Ethernet and field protocols like IO-Link has expanded rapidly over the last decade, offering increased data and integration potential. However, this explosion has resulted in confusion and a lack of expertise. It is critical, now more than ever, that suppliers have the right resources and expertise in place, and we are positioned to serve in an educational role as industry experts.

The role of expertise and innovation

The key challenge is choosing the network that best aligns with the strategic goals of the operation — whether that’s reducing downtime, lowering maintenance costs or enabling predictive analytics. Systems like IO-Link are not designed to be a new fieldbus, but an extension of an already rich field I/O landscape. Industrial Ethernet systems built for speed are not intended to be the most effective way of sending data to an ERP system.

While some may view the proliferation of communication protocols as a threat, it also represents an opportunity for industry leaders to demonstrate adaptability and expertise. The key is to present an unbiased, education-driven perspective that empowers users to make informed decisions.

Connectivity as the backbone of Industry 4.0

As Industry 4.0 continues to reshape manufacturing, connectivity is the backbone that enables data-driven operations. Australian industries are increasingly adopting predictive maintenance, autonomous systems and real-time analytics, none of which would be possible without rich data and robust networks.

It is therefore critical to understand the strengths and limitations of each platform within a specific context. Remote mining operations may prioritise network robustness and redundancy, while city-based manufacturing plants might focus on integrating IoT devices for smarter production lines. There is no single ‘best’ solution, but a range of options, each with their own benefits and drawbacks.

Technologies like LoRaWAN are required to help bridge gaps where cellular networks struggle. New technologies like Single Pair Ethernet (SPE) offer a glimpse into what the future holds. These systems will revolutionise process automation in industries like mining, robotics, automotive, water, energy, and oil and gas, and highlight a desire to minimise form factors while enhancing capabilities.

Navigating the road ahead

Balancing experience and embracing innovation are the two key elements as we journey forward. Industry players should approach connectivity challenges with an open mind, recognising that flexibility and continuous learning will be key to staying competitive.

We must foster a mindset of informed decision-making, supported by industry expertise. If we maintain this focus, Australian industries can navigate these complexities and run resilient, efficient operations that are ready for the digital future.

Conclusion

Increased connectivity is a pivotal factor in the future of process automation across Australia. While the challenges are genuine and multifaceted, they also offer opportunities for growth and differentiation. Industry experts, suppliers and end-users must collaborate to demystify and integrate meaningful solutions. Only through a collective effort and improved education can Australian industries implement best practices to reap the benefits of a connected future.

*Nicholas Everton is Bürkert’s Regional Business Development Manager for Systems in the East Pacific region. He has seven years of industry experience with Bürkert across several engineering disciplines, a tertiary degree in Computer Science and Networking from UNSW, and a passion for all things related to technology.

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