The findings show that 32% of surveyed IT Decision Makers admit they are currently relying on detection platforms originally built for IT and "adapted" for OT. This puts organisations at risk, as many are still trying to secure industrial environments with tools that were not designed to understand them.

This is concerning given that 63% of IT decision makers also cited that cyber incidents in the past 12 months resulted in direct operational downtime or impacted critical OT/ICS systems.

The research points to structural weaknesses in how incidents are managed across converged environments, as 28% of surveyed respondents still rely on manual or ad hoc coordination between their IT and OT security teams, while 37% of organisations have a shared platform for both IT and OT environments, but full technical integration needs to become a priority.

Richard Groome, OT cybersecurity specialist at e2e-assure, commented: "Most adapted IT platforms struggle in OT because they’re still thinking like IT tools. They can identify anomalies, but they often have no understanding of the business impact they have. OT downtime isn’t just a network problem; it’s a process problem, and if you can’t interpret what an alert means for a running plant or production line, you’re not preventing downtime, you’re just creating noise."

While extending IT platforms into OT is an obvious route to take, it creates a critical preparedness gap where organisations may have large volumes of data but lack the visibility needed to understand what it means in an operational context.

Without clear insight, teams are unable to interpret alerts or assess their impact on live environments, limiting their ability to act decisively. This is compounded by the fact that only 15% have deployed passive visibility tools specifically designed for industrial control systems, leaving many organisations without the real-time visibility required to translate data into actionable intelligence and reduce operational risk.

The challenge is becoming more acute as connectivity expands, as 70% of organisations have now fully or largely integrated cloud-connected environments into their IT/OT security strategies. However, without improvements in visibility and coordinated response, increased connectivity risks widen the gap between exposure and resilience.

At the same time, many organisations are unable to measure the effectiveness of their risk reduction measures, as 28% of businesses still rely on manual or ad hoc coordination between IT and OT teams, and only 37% operate a shared platform to deliver alignment and visibility across teams.

"The volume of data being ingested is often not understood or actionable, meaning incidents may still be missed. More connected does not automatically mean more secure, particularly where exposure increases faster than coordinated response capability," added Groome.

Encouragingly, organisations are beginning to recognise that the challenge is not simply a lack of technology, but how effectively it is used. Sixty-three per cent of leaders are increasing budgets for workforce training and role clarity, the highest prioritised budget area.

The research also highlights shifting priorities across OT security programmes, with supply chain risk emerging as a key area of investment following recent breaches. Investment now is critical, given that previously shared findings found the financial consequences of these preparedness gaps are rising, with almost a quarter (23%) of the most severe OT downtime incidents costing over £1 million, and 6% of incidents exceeding the £5 million mark.

Without purpose-built visibility and a distinctive IT and OT security strategy, organisations will continue to struggle to translate data into action, leaving the preparedness gap that threatens operational disruption. 

e2e-assure.com

Dr Rastegarpanah, assistant professor in applied AI and robotics at Aston, co-led research with Jamie Hathaway from the University of Birmingham’s Extreme Robotics Lab to overcome the ‘sim-to-real gap’. This is a longstanding challenge in robotics, referring to the difference between how robotics behave in simulation and how they behave in the real world, where there is variability, for example in materials, forces or sensor noise. This leads to unreliability.

Robots are trained for specific tasks, such as cutting, using simulation. However, collecting real-world data is expensive, slow, and sometimes unsafe, particularly for tasks involving physical interaction. The goal of the research, published in Scientific Reports, was to develop a method that combined the efficiency of simulation with the realism of physical environments, enabling robots to adapt without requiring large amounts of additional data.

By using AI to generate variations in conditions, the new training technique allows robots to transfer skills learned in simulation into the real world much more reliably, using only a small amount of real-world data. A robot can learn a complex task in a virtual environment, such as cutting or manipulating materials, and then adapt that knowledge to work effectively in real-world conditions, even when those conditions are uncertain or previously unseen.

Dr Rastegarpanah says that the method demonstrates that it is possible to achieve stable, efficient, and adaptive robot behaviour without requiring extensive real-world training. It could significantly reduce development time, cost, and risk. The impact is particularly strong in areas where robots must operate under uncertainty. This includes recycling and circular economy systems, such as battery disassembly, advanced and flexible manufacturing, and hazardous environments such as nuclear decommissioning.

The research was supported by the REBELION project, funded by UK Research and Innovation (UKRI) as part of a European collaborative research project on automated and safe lithium battery recycling.

Dr Rastegarpanah said: “This work shows that we can move beyond purely simulation-based training and achieve reliable performance in real-world conditions with minimal additional data. Our long-term vision is to enable plug-and-play intelligent robotic systems that can be trained in simulation and rapidly deployed in new environments with minimal reconfiguration. This could significantly accelerate innovation in areas such as sustainable manufacturing, recycling, and autonomous industrial systems.”

Visit www.nature.com/articles/s41598-026-41735-5 to read the paper in full.

www.aston.ac.uk/

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FOR TODAY'S manufacturers, automation is no longer a choice; it’s a business imperative. Speeding up production times, reducing energy costs, cutting waste and relieving the staffing burden caused by the manufacturing labour crisis, it’s no wonder that in factories across the UK and Ireland, robotic systems are being installed in increasing numbers – and not just in cutting-edge industries such as automotive and medtech, but also in traditionally manual-heavy sectors like food & beverage and packaging. 

However, not all automation solutions are equal. Before investing in a robotic system, it’s vital to ensure that any potential supplier understands your production needs and limitations, as oversights at this level can be costly. Here, we outline the seven key mistakes that every manufacturer should avoid when embarking on a new automation project, to make sure your installation runs smoothly from day one…

Mistake #1: Not taking into account your existing equipment

Any proposed new solution needs to easily integrate with your existing equipment, otherwise it will lead to production issues further down the line, reducing output and costing you money – essentially, creating more problems than it resolves.

A reputable supplier should want to visit your site and see for themselves the hardware and software systems that are already in place before recommending a solution that integrates well with both. At Tekpak, we use OPC UA for our automated packaging systems, a cross-platform, secure, open-source communication standard to enable convenient data exchange between our solution and the customer’s existing equipment. 

Our engineers will arrange a site visit at the start of every project to find out which signals are already in place and work these in when writing client-specific software, to ensure seamless integration from the point of installation. Make sure to have this conversation with your supplier at the start of your automation project – don’t let it be an afterthought.

Mistake #2: Not considering your available space

Manufacturing facilities are busy, often crowded spaces. And this rings especially true for packaging halls. Your dream automation solution may look great on paper but if its footprint is too large for your existing layout, you’ll be left with the costly dilemma of deciding whether to increase space, remove existing equipment or rework your new automation system.

We prefer to work ‘backwards’, beginning not with a proposed solution but from the starting point of the customer’s available space. This avoids logistical challenges further down the line. Ask your supplier if they offer a modular solution that can adapt to your layout constraints – not only will this keep down costs and limit installation difficulties, but it will also futureproof your operation, enabling you to increase production capacity as demand grows.

Mistake #3: Not thinking about day-to-day usability

Often, an automation project is specified by a technical or engineering manager, with input from the C-suite and finance teams. Yet, on a day-to-day basis, the people using the system will be operatives on the shop floor. To ensure your shiny new set-up isn’t left gathering dust in the corner of a workshop, it’s essential that it is easy to operate by employees who may not have advanced coding or engineering skills, and who may not even have English as their first language.

Simple HMIs with touch screens, intuitive menus, colour coding and clear visual cues – as opposed to lengthy technical jargon – will ensure your system can be widely used by all production staff, so check with your supplier that their systems are as user-friendly as this. 

At Tekpak, we always ask for feedback on usability from a variety of staff members following the FAT and SAT stages of a project, including those working on the shop floor. Making sure that operatives can easily alter packaging formats and layouts on the HMI, for example, is essential to the long-term success of your automation project.

Mistake #4: Not building in production flexibility

One of the biggest mistakes a manufacturer can make is choosing an automated system that’s perfect for them now. Automation is a big investment and consumer demands change rapidly. If your solution has been specified for one particular application, on one particular line, for one particular product, it may quickly become obsolete if your product range alters.

When we deliver a system to a customer, we make it clear that we’ve not merely sold them a machine but the software, too. We ensure that both can be altered as required, to offer maximum production flexibility now and in the future – whether that be a change of size, speed, product type or configuration. For example, we previously installed a high-speed vial coding line that was initially designed to handle three vial sizes. We are currently collaborating with the client to introduce a fourth, smaller format. Thanks to the original futureproof design of all modules, this addition can be implemented seamlessly without any mechanical modifications, providing full flexibility with no complications or unplanned downtime.

Mistake #5: Not having a single point of responsibility

An automated line may comprise equipment from numerous OEMS. However, for a project to succeed, the overall system needs to be ‘owned’, installed, managed and – most importantly – made compliant by one single company. Having a single point of responsibility will limit your risk, reduce admin load and speed up installation and delivery time, while giving you peace of mind that your solution meets the necessary regulations such as CE, Cyber Resilience and Machinery Directive, as well as validation requirements if applicable. 

Some companies go a step further. For example, one of our current customers has ordered additional equipment from a different supplier which will run alongside the robotic pick-and-place packaging cell we are building for them. We have arranged for this equipment to be delivered to our workshop so we can integrate it with our cell and ensure it’s running at the correct rate before it gets to the customer’s site – thereby increasing the chance of project success from day one.

Mistake #6: Not futureproofing your technology

Technology is changing fast. AI tools are becoming increasingly common in automation systems, with AI-enabled vision systems helping to position parts accurately, quality check products and increase worker safety, among other things. How can you ensure your automation system is fit for the AI revolution and won’t be outdated in a few years’ time, while remaining confident that your data is safe and secure? 

Firstly, check that your supplier’s software can be remotely updated as technology evolves and make sure any smart features are included in the FAT and SAT checks. In addition, ask if their solution is compliant with the incoming EU Cyber Resilience Act (CRA). Beginning in September 2026 with full enforcement taking place in December 2027, the CRA sets mandatory cybersecurity requirements for hardware and software products with a digital element. At Tekpak, all our systems are CRA-compliant as standard, well before the Act becomes enforceable.

Mistake #7: Not thinking about after care

Finally, don’t forget that your relationship with your automation supplier should not end at the point of installation – think of it as a partnership rather than a sales transaction. To ensure you get the best out of your system, your supplier should offer training, warranty and after-sales support for as long as you need it, including remote access to limit unexpected downtime.

After the SAT has been completed, our engineers usually remain on site for a week. After this, our service agreements and warranties, including remote access as standard, make sure our systems are never left unsupported. We’ll continue to support the customer for as long as they need us – in fact, we’re still caring for some machines 12 years after they were first installed. Make sure your supplier views your investment as a long-term partnership, not just a quick sale.

www.tekpakautomation.com

At the heart of this approach is the consistent reduction of interfaces. Instead of separate cables for power supply and data transmission, HySpeedVision enables a single-cable solution. This reduces cabling effort, saves space, simplifies integration, and simultaneously increases system reliability, especially in dynamic applications.

HySpeedVision supports serial high-speed protocols such as GMSL (versions 1–3), FPD-Link, APIX, ASA Motion Link, and USB. Additional protocols can be implemented upon request. With GMSL3, data transfer rates of up to 12 Gbps are achieved over distances of up to 12 m. Unlike Ethernet-based solutions, these technologies utilize deterministic point-to-point connections that ensure minimal latency and high process reliability. These characteristics are particularly relevant for applications in which image data is used directly to control machines and robots.

Mechanical resilience plays a central role, particularly in industrial robotics and moving systems. HySpeedVision is designed for use under demanding conditions and meets requirements such as drag chain compatibility and torsional strength. The system complies with the M12 standard per EN 61076-2-010, achieves IP67 protection, and is specified for a temperature range of –20 °C to +70 °C. The shielded version, with a frequency range from DC to 3.5 GHz, ensures electromagnetic compatibility even in environments with high levels of interference. Four power pins transmit up to 1.5 A at 24 V; two signal pins are provided for data transmission. 

www.rosenberger.com

AIRBUS AND Ericsson have successfully deployed a private 5G solution at the Airbus production site in Hamburg, with another deployment underway in Toulouse. This initiative forms part of Airbus’ ambitious digitalization strategy, aimed at strengthening manufacturing automation, traceability, and operational efficiency, while meeting the sector’s strictest safety and security standards. 

The partnership between Ericsson and Airbus leverages Ericsson Private 5G, recognized for its reliability, security, and high performance. The solution’s built-in infrastructure automation enabled rapid deployment across Airbus’ operations, significantly shortening implementation timelines compared to traditional setups. This automation allowed Airbus to scale connectivity quickly and securely across multiple sites. Close collaboration with the Ericsson product team ensured seamless integration, with the solution tailored to Airbus’ IT-tooling and cybersecurity requirements. The design’s modular architecture and API-driven interfaces simplified onboarding into Airbus’ existing systems, accelerating time-to-value and reinforcing robust security controls.  

Private 5G network

With a fully operational private 5G network now live in Hamburg and deployment at Toulouse underway, this rollout is part of a broader roadmap to extend private 5G across Airbus’ strategic sites in Europe, including further locations in Spain, the United Kingdom, and internationally, with projects in the United States pending.  

This effort reflects Airbus’ commitment to standardizing digital operations and scaling innovation across its global footprint. 

Hakim Achouri, 5G expert at Airbus, says: “Our objective is to migrate all our industrial networks towards 5G to ensure unified, ultra-reliable connectivity from the operator’s workstation to the aircraft cabin. This deployment accelerates projects involving 3D simulation, augmented reality, improved traceability for parts, and predictive maintenance for our assets. The standardization and scalability made possible by this architecture allow us to replicate the solution easily across further sites in Europe and worldwide.” 

Manish Tiwari, head of enterprise 5G, enterprise wireless solutions, Ericsson, says: “Our collaboration with Airbus embodies the alliance between technological innovation and  industrial excellence. Ericsson is proud to support Airbus’ digitalization ambitions through Ericsson Private 5G, offering best-in-class, secure connectivity at scale.” 

IoT integration

Ericsson Private 5G forms the backbone of Airbus’ strategic transformation projects, enabling high-value industrial use cases such as Internet of Things (IoT) integration, intelligent management of critical equipment, real-time quality control, and collaborative robotics. With seamless, full-site coverage with private 5G, machines and operators on the production floor gain true mobility, boosting productivity, process agility, and end-to-end industrial control, all of which are key to realizing the full potential of Industry 4.0.  

This new phase underscores Airbus and Ericsson's commitment to the future of industrial connectivity, featuring advanced 5G Standalone (SA) technology and next-generation deployment models, which are also poised to accelerate 5G usage in office environments. Additionally, joint R&D efforts focus on connected cabins, 6G, and nonterrestrial networks (NTN), enhancing the connectivity ecosystem for aerospace and smart manufacturing applications. Through this strategic partnership, Airbus and Ericsson are accelerating the digital transformation of the aerospace industry, laying the foundation for the next generation of smart factories — fully connected, scalable, and sharply focused on innovation across Europe and the world. 

Find out more about similar projects by visiting Stand K124 and the Connected Production Theatre, where Ericsson will be presenting rhought the two days of the exhibition.

www.ericsson.com

VISIBILITY GAPS remain a major obstacle in industrial cybersecurity. In its 2026 OT threat reporting, Dragos estimates that "fewer than 10% of OT networks worldwide currently have meaningful network monitoring in place", leaving defenders with limited insight into malicious activity until an incident is already underway.

But simply bolting traditional IT visibility tools designed for servers and endpoints into OT networks can, and often does, create instability or degraded performance. To protect cyber and operational resilience, manufacturers need an engineering-led view of network insight that respects uptime and live production.

The visibility paradox

Traditional IT security tools often rely on active scanning or inline inspection, methods that can create latency in fragile control systems if they are used carelessly.

Take industrial controllers supporting live production processes. These systems rely on real-time communications to keep machinery operating within expected tolerances. Unexpected scans or intrusive network testing can introduce delays or disrupt those communications, which in turn can affect output, quality or availability.

Paradoxically, organisations cannot secure what they cannot see. Yet attempting to observe these networks using conventional IT methods can destabilise the very systems they are trying to protect.

As NIST states in its Guide to Operational Technology (OT) Security, "OT network owners should exercise extreme caution when permitting active scanning on an operational network due to device sensitivity on the target network. Active scans may cause device instability or interfere with the device process state, potentially impacting safety and integrity."

Passive monitoring resolves this. By observing network traffic through engineered SPAN or TAP connections, it gives operators a way to understand communications without interacting directly with sensitive devices. That makes it better suited to fragile environments where active scanning may introduce operational risk.

In live manufacturing environments, these approaches should be designed and validated before they are rolled out. Passive monitoring across plant networks can support continuous asset discovery and exposure analysis without adding traffic to production systems. That helps replace incomplete manual inventories with a clearer picture of operational assets and communications.

Scalable resilience

Visibility alone does not reduce risk unless it informs how networks are structured and governed. In many organisations, OT systems that run machinery are connected to the wider business network without enough planning or separation.

That creates unnecessary exposure. Once a business network is compromised, attackers can move more easily towards critical operational systems. Legacy OT devices often cannot support modern security agents or deep packet inspection, which leaves them particularly exposed when networks are merged without clear boundaries.

The next step is turning visibility into controlled, resilient infrastructure. As the NCSC notes in its secure connectivity principles for OT, connectivity "should be designed with operational resilience in mind, and should not compromise the safety, reliability, or availability of OT systems."

The progression is straightforward. Organisations first need to identify connected assets and communication flows so they understand how systems behave under normal conditions. Segmentation can then be introduced through methods such as VLANs and network isolation to separate domains according to operational importance or trust level. Continuous monitoring then helps ensure those boundaries remain effective over time.

In manufacturing environments, network security should be embedded into the architecture from the outset. Manufacturers looking to strengthen resilience across industrial environments should start by asking not just whether they can see their environments, but whether they can do so safely and continuously.

Carl Henriksen is CEO at OryxAlign

www.oryxalign.com

The company, which is headquartered in Leek, the Netherlands and expanded into the UK in 2025, is also celebrating its 20th anniversary as a leading provider of refurbishment and repair services for industrial electronics. 

The Buyback scheme enables businesses to dispose of surplus, obsolete or faulty industrial electronics free of charge, while also generating revenue from equipment that might otherwise be discarded. 

Obsolescence in industrial products has long presented a challenge, often leading to unnecessary waste when older components are discarded prematurely. Instead of Waste Electrical and Electronics Equipment (WEEE) compliant disposal fees, businesses can now generate revenue from equipment that would otherwise be thrown away. 

The JC-Electronics’ experienced team will visit customer sites to assess surplus stock, provide guidance on long-term equipment support and offer a competitive price for viable products. This removes the need for organising skips or arranging disposal, helping companies to reduce costs and streamline operations. 

Visitors to Smart Manufacturing Week can enter the ‘Golden Ticket’ initiative at the JC-Electronics stand G110 for a chance to win £500 off their next repair. No purchase is necessary and the prize can be applied to any repair service. 

Dan Jones, buyer at JC-Electronics, said: “This new scheme encourages companies to explore alternative ways of managing obsolete machinery, supporting more sustainable supply chains while ensuring compliance with WEEE regulations.”

With a team of 140 specialised technicians, JC-Electronics repairs, refurbishes, calibrates and tests every product to the highest standard to achieve the JCertified warranty seal. This supports effective management of the industrial electronics supply chain while delivering sustainable and cost-effective automation solutions. 

Jones continues: “We want to demonstrate that there is a viable alternative through the use of refurbished industrial automation spare parts. For the past 20 years, by choosing JCertified refurbished electronics, customers have reduced their consumption of water, raw materials, CO2 emissions and benefited from a two-year warranty.” 

jc-electronics.com/uk

CRITICAL FOR passenger safety and comfort, lift and elevator controllers also increasingly rely on digital and connected technology for energy efficiency and remote condition monitoring, driving the need for advanced control solutions. 

Peter Roberts, project manager at manufacturer of traction and hydraulic lift and escalator controllers and accessories, Lester Controls, says: “Our technology provides accurate positioning and speed of lifts and elevators, and meets all the strict safety regulations in the event of a power failure."

"We’re also responding to the industry’s trend towards digital and energy-efficiency, which doesn’t have to be tied only to high-cost investment of new infrastructure. For lift and escalator applications, both new and existing, controllers must be digitally connected, sending data to the cloud via the internet or mobile phone network. Maintenance engineers use this information to diagnose faults remotely and arrive on site with the right spares and tooling. That cuts operational costs by reducing the number of site visits."

"Another popular feature is energy-saving. We can automate escalators to go-slow or stop at quiet times, and we often add energy recuperation or variable speed control for lifts."

A particular challenge for Lester Controls is that every building is different, with lift control logic varying depending on the number and type of lifts and escalators. Each project needs a dedicated controller to be designed, built, and tested. This is a complex process that requires accuracy over every detail. That is why Lester Controls has adopted ETAP SEE Electrical as the CAD package it uses to create electrical schematics.

The challenge

When designing new lift and elevator controllers, there are many variables at play. These include the number and types of lifts and elevators, the control philosophy, energy-saving features, and requirements for remote monitoring and communications. 

All of these requirements lead to unique functionality for each project. In turn, this requires a unique arrangement of components such as PLCs, motors drives, switches and HMIs for each project. Lester Controls’ engineering team uses specialist CAD software to design and manufacture its controllers.

A cabinet might contain up to 160 individual components. Any error can lead to delays in the workshop, as production engineers need to raise queries and resolve issues when they are building the cabinets. These errors can be avoided with modern software, which includes features such as contact registers. 

As Roberts explains: "A customer got in touch in 2020 to request that we use specific symbols in our drawings. As these were standard symbols that are in the latest technical standards, we realised it was time to upgrade to a modern intelligent CAD package."

The solution 

"We evaluated all of the software packages on the market and came to the conclusion that ETAP SEE Electrical was best for our needs. It’s a software package from Schneider Electric, a collaborative supplier of components for our controllers and a long-standing member of our ecosystem. It comes with technical support and training resources, has flexible licensing and supports all the symbols in the latest standard."

"We wanted an intelligent package that would enable us to reuse the data from drawings. For example, we need to export parts lists in CSV format for upload into our parts management system, and we needed it to integrate with our existing printer for identification labels. We also needed to interface with our cutting machine, as well as our manufacturing resource planning (MRP) software."

"Another important feature was an automated register of electrical contacts. With old CAD package, we had to reconcile these individually, which was painstaking work. Any loss of focus could result in duplicate contacts in a drawing, leading to technical queries from the workshop, taking more time to resolve."

"After installing the software, I picked up the task of reworking all of our existing drawings in the new software. Balancing it alongside project work, it only took eight months to convert around 200 master drawings and 800 symbols. I found the new software easy to pick up with tutorial videos, PDF guides, and support from Schneider Electric."

"Since then, it’s been fairly easy to roll out to the team, which includes seven designers and three technical staff. We also brought on a new designer, who learned it after seeing the basics and getting a couple of drawings. Nobody in the team has had major questions, it has worked flawlessly and has future-proofed operations as new staff are brought onto the workforce."

"The big result is that the software has saved nearly half of our design time. Previously, a major contract would require about five days of design and a lot of manual data entry but now it’s three days. Typically, a major project has around 160 components and we’d need to manually paste part numbers and descriptions to create a parts list that corresponds to each drawing. But now we can simply extract the data from the software as a CSV file."

"The software has also reduced the number of design errors. Because it includes a register of contacts, we no longer get duplicate contacts. That means we have fewer technical queries to resolve with the workshop, saving more time and offering more value to customers."

etap.com/home

According to the court’s decision, Elite Robots Germany is immediately prohibited from offering or distributing the infringing software and all products containing this software in Germany until further notice.  Moreover, Elite Robots Germany is obligated to provide comprehensive information about the infringing acts it has committed and, in doing so, also to disclose information about the customers it has supplied. Teradyne Robotics intends to take legal action against Elite Robots’ distributors and partners if they continue to offer the infringing software.

“At Teradyne Robotics, we have chosen to take a stand against any competitors copying our proprietary hardware or software design and we are of course pleased with this ruling,” said Jean-Pierre Hathout, president of the Teradyne Robotics Group. “We believe we have irrefutable evidence of copyright infringement and, while this is not a final ruling from the court, it is a clear indication that we have a very strong case.”

Hathout adds: “Automation and innovation are critical to our industrial future. We cannot passively allow companies to unlawfully copy protected technologies. This not only hampers research and innovation but also undermines customer experience and confidence. Teradyne Robotics remains fully committed to protecting our intellectual property and to ensuring automation customers have access to the safe, innovative and high-quality solutions they deserve.”

www.teradyne.com

INDUSTRIES TODAY face a complex mix of pressures that make sustainable automation essential. Environmental responsibility is among the most visible. Industrial operations contribute significantly to global energy consumption and carbon emissions, and automation systems, particularly in manufacturing, assembly and logistics, are often energy-intensive. Material waste is another pressing concern. Scrap, defective products, and packaging inefficiencies increase costs and place additional strain on the environment. Sustainable automation addresses these challenges while delivering measurable economic benefits.

Rising energy costs and market volatility add urgency. Organisations that invest in energy-efficient equipment and process optimisation can achieve significant cost reductions. For example, a mid-sized automotive facility that replaced standard motors with high-efficiency variable-speed alternatives reduced electricity consumption by 20%, resulting in annual savings of more than £400,000. Process optimisation aimed at reducing material waste can have a substantial impact, particularly in industries where raw materials account for a large share of production costs.

Regulatory requirements further accelerate adoption. Across the UK and EU, carbon pricing mechanisms, mandatory energy reporting and emissions reduction targets establish clear expectations. Compliance with standards such as ISO 50001 provides a structured approach to improving energy performance, while transparent reporting strengthens stakeholder confidence. Organisations that address sustainability proactively can reduce regulatory risk, strengthen credibility and in some cases access financial incentives for early action.

Principles of sustainable automation

Sustainable automation rests on four key principles: energy efficiency, waste minimisation, lifecycle sustainability, and intelligent process management.

- Energy efficiency is foundational. Automated systems should operate only when required, and equipment such as motors, drives, conveyors and robotics must be correctly sized and configured to minimise power consumption. AI-driven scheduling and regenerative technologies can further reduce energy demand. In one industrial automation project, the introduction of regenerative robotic arms, combined with AI-based scheduling, reduced energy use by more than 20%, delivering annual savings of £350,000 and significantly lowering carbon emissions. When applied at scale, decisions like these have a substantial cumulative effect.

- Waste minimisation focuses on preventing scrap, rework, and inefficient use of materials. Robotics and precision automation improve accuracy, while sensors and analytics detect inefficiencies before they escalate. Closed-loop recycling systems, where scrap materials are reintegrated into production, further reduce waste. In electronics manufacturing, precision robotic assembly reduced defective product rates by 30%, cutting material waste and lowering disposal costs.

- Lifecycle sustainability requires organisations to consider environmental impact from system design through to end of life. Selecting recyclable materials, designing equipment for maintainability and planning responsible disposal ensures sustainability is addressed from the outset rather than added later. Predictive maintenance extends equipment lifespan and reduces unnecessary replacement, delivering both environmental and financial benefits.

- Intelligent process management ensures continuous improvement. IoT sensors and digital twins enable real-time monitoring of energy use, material consumption, and machine performance. AI-driven analytics identify inefficiencies and recommend operational adjustments before issues emerge. In food processing environments, AI-based production scheduling reduced energy consumption during peak periods while lowering spoilage, demonstrating how intelligent management can improve efficiency and sustainability simultaneously.

Enabling technologies

Numerous technologies enable sustainable automation, each contributing distinct capabilities. However, the greatest gains are achieved when these technologies operate as an integrated system rather than in isolation.

Robotics and smart manufacturing systems improve accuracy, reduce human error, and lower material waste. Energy-efficient drives, regenerative technologies, and intelligent scheduling reduce power consumption, while integrated control systems ensure different parts of the operation communicate effectively, limiting inefficiencies across production and logistics.

Artificial intelligence and machine learning play a critical role in predictive maintenance, process optimisation and demand forecasting. Predictive maintenance reduces unplanned downtime and extends equipment life, while process optimisation supports more energy-efficient production. Accurate demand forecasting aligns output with actual market requirements, helping to reduce excess inventory and material waste. In a large packaging facility, AI-based scheduling reduced peak-hour energy consumption by 18% and lowered spoilage by 12%.

Industrial IoT provides the real-time data required for informed decision-making. Sensors monitor energy usage, machine performance and environmental conditions, generating actionable insights. By analysing this data, organisations can identify inefficiencies, prevent waste and continuously optimise production processes.

Renewable energy integration complements automation technologies by reducing reliance on grid electricity. Solar, wind and biomass systems can supplement or replace traditional energy sources, lowering carbon emissions. Smart energy management systems coordinate renewable energy supply with production schedules. This helps maintain operational continuity while maximising the use of low-carbon power.

The common thread across these technologies is integration. Robotics alone does not reduce energy consumption and renewable energy alone does not eliminate waste. Meaningful results come from connecting systems, processes and people so they operate as one.

Strategic recommendations

For leaders considering investment in sustainable automation, the path forward can be summarised into a few key actions.

- Start with insight, not technology. Organisations should begin by auditing energy use, waste and operational performance to build an accurate view of where improvement will deliver the greatest value. This clarity helps prevent misallocation of capital and ensures efforts are focused on areas with the strongest impact.

- Design holistically. Automation should be approached as a connected ecosystem rather than a collection of isolated assets. Software, hardware, energy, maintenance and people must work together. Integration should be a design principle, not an afterthought.

- Prioritise lifecycle value. Decision-making should extend beyond initial purchase cost to consider total cost of ownership. Maintenance requirements, energy consumption, operational lifespan, recyclability and carbon impact all influence long-term value. In many cases, the most sustainable option is also the most financially resilient.

- Invest in people. Sustainable automation depends on skills as much as technology. Developing capability in energy management, automation systems, data analytics and sustainability leadership strengthens execution. When teams understand the purpose behind the technology, adoption improves and outcomes become more consistent.

- Build strong partnerships. No organisation delivers sustainability in isolation. Collaboration with technology providers, integrators, energy specialists, academic institutions and supply chain partners enables access to broader expertise and shared learning, leading to more effective outcomes.

- Measure, review, improve. Sustainability performance is not static. Continuous measurement, review and adjustment are essential. Embedding sustainability metrics into day-to-day operations ensures progress is monitored consistently rather than treated as an annual reporting exercise.

- Embed cultural ownership. Sustainability should form part of organisational identity. Recognising success, sharing results and encouraging innovation at all levels fosters shared ownership. When sustainability is embraced collectively, it becomes a sustained capability rather than a top-down directive.

When organisations follow these principles, sustainability moves beyond cost containment. It becomes a strategic capability that supports long-term resilience, performance and value creation.

Dan Migliozzi is sales director for the UK, EU and North America at AGITO Global

agitoglobal.com