What is Industrial Processes? Explained with Automation Insights
Industrial processes are at the heart of modern manufacturing and production systems, enabling businesses to transform raw materials into finished goods on a massive scale.
With the rise of industrial automation systems, these processes have become more efficient, precise, and scalable, driving innovation across industries.
But what truly defines an industrial process? While many articles cover the basics, this blog will dig deeper into the overlooked nuances that set industrial processes apart, offering a fresh perspective for engineers, manufacturing professionals, and supply chain managers.
Introduction to Industrial Processes
Industrial processes serve as the backbone of large-scale manufacturing and production. They encompass a series of technical processes working together to modify the state of materials, energy, or information, ultimately delivering desired end products.
But these processes are more than just technical operations; they represent a symphony of systems, technologies, and methodologies, often leveraging automation through programmable logic controllers (PLCs) and other advanced tools.
This blog will provide:
- A detailed understanding of industrial and technical processes,
- Insights into how industrial automation systems enhance these processes,
- Answers to commonly overlooked questions about their integration and operation.
If you’ve been searching for a distinct angle on industrial processes, you’re in the right place. Let’s break it down.
What is a Technical Process?
A technical process refers to a procedure that alters the state of materials, energy, or information, transitioning them from an initial state to a final state.
These changes could involve physical, chemical, or positional modifications.
A Simple Example of Technical Processes
Let’s dissect an example to make the concept clearer. Imagine the production of molded plastic items. Here’s how various technical processes would appear in a typical sequence:
| S/N | Initial State | Technical Process | Technical System | Final State |
| 1 | Two pure materials (A & B) | Blending/Mixing | Blend Tank | Homogeneous mixture of A & B |
| 2 | Solid Mixture | Heating | Moulding Machine | Molten fluid mixture |
| 3 | Molten Mixture | Reforming and Cooling | Mold Core | Solid, shaped material |
| 4 | Material at Point A | Position Change | Conveyor | Material at Point B |
This sequence illustrates how individual technical processes contribute to achieving the desired final output. But when multiple technical processes operate collaboratively on a large scale, they form the foundation of an industrial process.
What is an Industrial Process?
An industrial process involves the integration of multiple technical processes to produce one or more end products, typically on a massive scale. These processes are designed for efficiency, scalability, and precision, often incorporating advanced technologies like industrial automation systems.
Key Characteristics of Industrial Processes
- Integration of Systems: Combines various technical processes and systems to achieve a unified goal.
- Scalability: Operates on a large scale to meet industrial production demands.
- Automation and Control: Leverages automation tools such as PLCs to enhance accuracy and efficiency.
- Customisation: Adaptable to different production requirements and product specifications.
Example of an Industrial Process
Plastic injection molding is a classic example. It involves:
- Raw material preparation,
- Melting and molding of material,
- Solidification and shaping,
- Transfer of finished products via automated conveyor systems.
Each of these steps contains a set of technical processes working together to produce high-quality, uniform plastic items efficiently.
But beyond the basics, modern industrial processes are evolving. Let’s explore how automation and advanced technologies are reshaping this domain.
How Industrial Automation Systems Transform Industrial Processes
Industrial automation systems play a pivotal role in enhancing the efficiency, accuracy, and reliability of industrial processes. By integrating advanced technologies like AI, IoT, and robotics, these systems address some of the biggest challenges in manufacturing and production.
Core Components of Industrial Automation Systems
- Programmable Logic Controllers (PLCs):
- PLCs act as the brains of automation, controlling and synchronizing various machinery and workflows.
- Popular brands include Siemens, Allen-Bradley, and Mitsubishi Electric.
- Sensors and Actuators:
- Sensors gather real-time data such as temperature, pressure, and position.
- Actuators perform physical actions like movement or heating based on PLC commands.
- Human-Machine Interfaces (HMIs):
- HMIs allow operators to monitor and control automated systems with ease.
- Supervisory Control and Data Acquisition (SCADA):
- SCADA systems oversee and analyze the entire production process, ensuring optimal performance.
Benefits of Automation in Industrial Processes
Improved Efficiency: Automation streamlines repetitive and time-consuming tasks, increasing overall productivity.
Enhanced Consistency: With precise control and monitoring, automation eliminates variations, ensuring uniform quality.
Reduced Human Error: Automated systems reduce the likelihood of mistakes, enhancing safety and reliability.
Real-time Monitoring: Advanced automation tools provide live insights into process performance, enabling quick decision-making.
For example, in the context of our plastic injection molding example, automation ensures precise material blending, consistent heating profiles, and accurate molding time while minimizing waste.
Exploring the Overlooked Nuances of Industrial Processes
Most discussions on industrial processes focus on their technical or economic aspects. However, there are overlooked dimensions that deserve attention:
1. The Role of Sustainability
With growing concerns about environmental impact, industrial processes are increasingly designed with sustainability in mind. Techniques like energy recycling, waste minimization, and eco-friendly raw materials are gaining traction across industries.
2. Human-Machine Collaboration
While automation reduces reliance on human intervention, skilled operators remain essential. The collaboration between human expertise and machine precision ensures optimal results, particularly in complex or high-stakes manufacturing.
3. Data as an Asset
Industrial processes generate vast amounts of data. Advanced analytics and AI algorithms can extract valuable insights from this data, identifying inefficiencies, predicting maintenance needs, and driving innovation.
4. Adapting to Industry 4.0
The Industrial Internet of Things (IIoT) is transforming traditional processes. By connecting machinery and systems through IoT platforms, businesses gain unmatched control and flexibility, paving the way for smart manufacturing.
By addressing these factors, businesses can not only improve their processes but also future-proof their operations.
Take Your Understanding of Industrial Processes to the Next Level
Industrial processes and automation systems together form the foundation of modern manufacturing.
By integrating technical processes, leveraging advanced automation tools, and addressing overlooked nuances like sustainability and IIoT, businesses can achieve unprecedented efficiency, precision, and innovation.
To unlock the full potential of industrial automation, start by understanding the role of PLCs, IoT integration, and data analytics in your own processes.
Need guidance? Explore the latest tools and technologies, and ensure your business stays ahead of the curve.
Mastering industrial processes is no longer optional; it’s a competitive necessity.