Opening new doors together

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Opening new doors together

How can disruptions be turned into opportunities? In the Insight Sessions at the Global Forum, Endress+Hauser customers and partners shared how they are dealing with the major challenges facing the process industry. Here are the five key takeaways.

1 Accurate data is the starting point

When it comes to digital processes, artificial intelligence, sustainability or the circular economy, without precise and reliable data, transformation projects go nowhere. Data provides insights into processes, uncovers efficiency potential and makes progress measurable. Incorrect or unreliable data leads to wrong decisions or inefficient processes, following the 'garbage in, garbage out' principle. By investing in data quality as well as in precise and reliable measurement technology, companies lay the foundation for successful transformation. Against this backdrop, sensors that monitor quality parameters in real time during the process are attracting increased attention: Contract manufacturer Lonza, for example, demonstrated how it optimizes bioprocesses using Raman spectroscopy. And new insights into existing plants are also possible. Masco Group Automation presented how it uses non-invasive measurement technology to implement IIoT solutions in regulated facilities in the life sciences industry.

2 Digitalization creates immediate value

Beyond the measured value itself, smart measurement devices provide a wealth of data that allows insights into the sensor and the process. With digital communication protocols such as HART, PROFIBUS, Ethernet APL, IO-Link, wireless technologies and soon Single Pair Ethernet, the process industry can tap into this treasure trove of data. IIoT ecosystems and digital applications make it possible to transform data into information by processing it, placing it in the right context and visualizing it. The benefits are immediately apparent - in greater efficiency, safety and quality. Specialty chemicals manufacturer Nouryon demonstrated how it used sensor data and digital models at one site to extend calibration intervals and thereby reduce plant downtime. An example from the US showed how a wastewater treatment plant with 1,200 measuring instruments can operate with just two technicians thanks to digitalization - in part because remote fault diagnosis and troubleshooting are possible.

3 AI is finding its way into real-world applications, but it is not a panacea

Artificial intelligence is the promising technology of our time. It is expected to solve complex problems and take plant automation to a new level through continuous predictions. The Insight Sessions at the Global Forum 2026 made it clear that AI is now more than just a buzzword in the process industry - it is finding its way into practical applications. The French company Purecontrol presented an AI solution for water, wastewater and waste management. It determines optimal control strategies based on internal and external data. These are then implemented in the programmable logic controller. Performance and energy savings have already been maximized in over 600 plants; for example, in the aeration process of wastewater treatment plants. However, AI is not 'plug and play.' It must first prove its economic value, gain trust and, above all, it needs the right data. Furthermore, AI is just one tool among many. Depending on the challenge, simpler, rule-based approaches - that is, classic algorithms without learning components - are often the more suitable solution.

4 Sustainability pays off

To reduce their environmental footprint, companies are increasingly turning to process optimization. This not only reduces their consumption of energy, water and raw materials but also lowers costs at the plant level. Projects undertaken by various plant manufacturers demonstrate the significant potential for efficiency gains: In the life sciences industry, optimizing a plant for the production of water for injection resulted in savings in the millions over the plant's entire lifespan. In clean-in-place (CIP) processes at breweries, a new solution has reduced the number of cleaning cycles by 30 percent. At the same time, the need for sustainability is leading to entirely new technologies and business models. One example is Streamline Innovations. Using a new process, the US company chemically converts hydrogen sulfide into elemental sulfur, thereby making heavy industry more environmentally friendly. Launched 10 years ago, it is now a company with an annual revenue of over $100 million.

5 Today, innovation requires co-creation

The world is becoming increasingly complex, new technologies are evolving at a rapid pace and everything is interconnected: That is why no company can navigate this transformation on its own. Co-creation is essential for quickly developing transformative products and solutions and jointly creating value that benefits all stakeholders. In the process industry, collaboration on equal terms between sensor manufacturers, plant builders, automation specialists, end customers and other partners is becoming a decisive lever. It replaces traditional supplier relationships and is characterized by transparency, knowledge sharing and trust. As a result, better planning is possible throughout the entire supply chain. This provides customers with products and solutions that meet their needs - and helps companies reduce development risk.

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