By Hennie Colyn, direct sales executive, Process Automation at Schneider Electric.
Today’s brownfield plants are typically characterised by outdated equipment and processes, and face challenges ranging from inefficient operations to safety hazards. However, all is not lost as these plants stand to gain a lot from digitalisation. In contrast to their greenfield cousins, brownfield plants are generally underused or even abandoned, which makes digitalisation even more compelling as the infrastructure already exists and can be modernised with substantial benefits.
Indeed, the integration of digital technologies has the potential to not only address the abovementioned challenges but also to move brownfield plants back into the twenty-twenties, so that they can benefit from increased efficiency, safety and sustainability.
The journey towards digitalisation has important sustainability benefits such as:
• Reduced fossil fuel demand: digitalisation aids in optimising energy usage, leading to a reduction in fossil fuel demand in manufacturing processes.
• Improved green total factor energy efficiency: the adoption of digital technologies enhances overall energy efficiency, contributing to greener and more sustainable operations.
• Decline in pollution-intensive production: digital transformation reduces the production scale of pollution-intensive enterprises, mitigating their environmental impact.
• Carbon and greenhouse gas (GHG) emission reduction: through advanced data analytics and automation, brownfield plants can actively monitor and reduce carbon and greenhouse gas emissions, aligning with global sustainability goals.
Hennie Colyn, direct sales executive, Process Automation at Schneider Electric.
Despite the above benefits, there will also be some challenges. Like many new or ongoing projects, resistance to change is often the greatest barrier of all. Humans are habitual creatures and the adage “if it’s not broken, don’t fix it” sums it up nicely. Here it’s important to roll out a change management strategy that educates employees on the importance of modernisation through digitisation and automation.
Similarly, the changeover must keep pace with the needs and expectations of customers, ensuring that change management is handled in a sensitive manner.
Importantly, a clear vision for the transformation must be communicated to ensure the abovementioned resistance is handled in a productive manner, ultimately leading to operations that are agile and make the most of this new era.
To bring a brownfield plant back to life, consider the following important steps:
• Evaluate your current digital landscape and identify areas for improvement.
• Foster a culture that embraces change, coupled with transparent communication to address concerns and build consensus.
• Optimise existing processes to integrate digital technologies seamlessly for maximum efficiency.
• Prioritise data management and curation to harness the full potential of digital technologies.
• Identify and deploy technologies tailored to the needs of brownfield plants.
• Develop a skilled and adaptable workforce capable of leveraging digital tools effectively.
• Collaborate with reliable technology partners to ensure a smooth and successful transition.
Optimising the product design process Siemens South Africa
IT in Manufacturing
OPmobility is partnering with Siemens to adopt its Teamcenter X Product Lifecycle Management software. OPmobility’s increasingly complex products now include electronics and software, to create energy storage systems, which include battery and hydrogen electrification solutions and fuel tanks.
Read more...Why turbomachinery should break free from vendor lock-in Schneider Electric South Africa
Motion Control & Drives
Today’s modern turbomachinery control systems form an important of operational efficiency, be it in heavy industries, traditional power generation or renewables such as hydroelectric facilities. Independence is the name of the game, and turbomachinery stands to gain lot from this newfound freedom.
Read more...Smart milling for resilient, sustainable food production
IT in Manufacturing
As the global demand for food continues to rise due to increasing urbanisation, the milling industry faces the challenge of balancing efficiency with sustainability. Bühler is committed to making milling more energy-efficient while maintaining high operational performance. Its solutions allow mills to reduce energy costs and ensure long-term sustainability.
Read more...The evolving landscape of data centres in the age of AI Schneider Electric South Africa
IT in Manufacturing
The data centre industry is undergoing a period of rapid transformation, driven primarily by the explosive growth of AI. It’s clear that the demands of AI are reshaping the very foundations of data infrastructure. This isn’t merely about incremental upgrades; it’s a fundamental shift in how we design, power and operate these critical facilities.
Read more...Monitoring partial discharge on medium voltage switchgear Schneider Electric South Africa
Electrical Power & Protection
Schneider Electric South Africa has launched its EcoStruxure Service Plan (ESP) in the Anglophone African region for medium voltage (MV) switchgear
Read more...SA Food Review
IT in Manufacturing
Food Review is a monthly trade journal for South Africa’s food and beverage manufacturing industry, for industry professionals seeking detailed information on trends, technologies, best practices and innovations.
Read more...Keeping an eye on oil consumption with moneo ifm - South Africa
IT in Manufacturing
Manufacturing companies in the metal industry need oils and other fluids that are consumed by their machines. To make this consumption transparent and to establish a link to the ERP system, Arnold Umformtechnik relies on the IIoT platform, moneo, in combination with the SAP-based software solution Shop Floor Integration (SFI) – both from ifm.
Read more...AI accelerates energy transformation RJ Connect
IT in Manufacturing
With the rapid expansion of generative AI applications, data centre power demand is reaching unprecedented levels.
Read more...Revolutionising mining operations with MineOptimize
IT in Manufacturing
Now more than ever, mining and mineral processing companies need to boost productivity, ensure safety, and protect the environment. ABB’s comprehensive electrification, automation and digital solutions portfolio is ideally positioned to meet these challenges across all mining processes, from mine to port, transforming performance in a digital world.
Read more...Buildings in Africa’s urban evolution Schneider Electric South Africa
IT in Manufacturing
Africa is now an urban continent. How does the continent mobilise to accommodate urban dwellers and maintain and implement critical infrastructure that allows for this expansion? Building management systems provide a tangible solution to optimise resource use, lower operations costs and ultimately contribute to a growing continent that also employs green practices.
printer friendly version