Industrial Processes: Explained with Automation Insights
Industrial Processes
Industrial processes are at the heart of modern manufacturing and production, transforming raw materials into finished goods on a massive scale.
With industrial process automation, these operations have become more efficient, precise and scalable. But what are industrial processes, and what defines them? This guide explains the basics, gives examples, and covers how automation changes the way industrial operations run.
What is a Technical Process?
A technical process is a procedure that alters the state of materials, energy or information, moving them from an initial state to a final state. The change can be physical, chemical or positional.
A Simple Example of Technical Processes
Take the production of moulded plastic items. The technical processes run in this 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 | Mould Core | Solid, shaped material |
| 4 | Material at Point A | Position Change | Conveyor | Material at Point B |
When several technical processes work together on a large scale, they form an industrial process.
What is an Industrial Process?
An industrial process integrates multiple technical processes to produce one or more end products, typically on a massive scale. It is designed for efficiency, scalability and precision, and often relies on industrial automation systems. Process industrial sectors such as chemicals, food and beverage, oil and gas, and water treatment depend on these processes every day.
Key Characteristics of Industrial Processes
- Integration of Systems: Combines technical processes and systems to achieve a unified goal.
- Scalability: Operates at the scale industrial production demands.
- Automation and Control: Uses tools such as PLCs to improve accuracy and efficiency.
- Customisation: Adapts to different production requirements and product specifications.
Industrial Processes Examples
Plastic injection moulding is a classic example. It involves:
- Raw material preparation
- Melting and moulding of the material
- Solidification and shaping
- Transfer of finished products via automated conveyor systems
Each step is a set of technical processes working together to produce uniform, high-quality plastic items. Other common examples include chemical processing, food and beverage production, metal fabrication, and water and wastewater treatment.
Industrial Process Automation: How Automation Systems Transform Industrial Processes
Industrial automation systems improve the efficiency, accuracy and reliability of industrial processes. By combining controllers, sensors, software and increasingly AI, IoT and robotics, they address some of the biggest challenges in manufacturing and production.
Core Components of Industrial Automation Systems
- Programmable Logic Controllers (PLCs): The controllers that run and synchronise 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 act on PLC commands, for example by moving a valve or switching a heater.
- Human-Machine Interfaces (HMIs): HMIs let operators monitor and control automated systems.
- Supervisory Control and Data Acquisition (SCADA): SCADA systems oversee and analyse the whole production process from a central point.
Benefits of the Automation of Industrial Processes
- Improved Efficiency: Automation takes over repetitive, time-consuming tasks and increases productivity.
- Enhanced Consistency: Precise control removes variation and keeps quality uniform.
- Reduced Human Error: Fewer manual steps mean fewer mistakes and a safer plant.
- Real-time Monitoring: Live process data supports faster decisions.
In the injection moulding example, automation keeps material blending precise, heating profiles consistent and moulding times accurate, while minimising waste.
Overlooked Nuances of Industrial Processes
Most discussions of industrial processes focus on the technical and economic side. Four other factors matter just as much.
Sustainability. Energy recovery, waste minimisation and lower-impact raw materials are now design requirements, not extras (see the UN’s goal on responsible production). Plants are increasingly measured on energy and water use per unit produced.
Human-machine collaboration. Automation reduces manual intervention, but skilled operators and maintenance teams are still essential, especially during start-up, faults and changeovers.
Data as an asset. Industrial processes generate large volumes of data. Analytics can reveal inefficiencies and predict maintenance needs before equipment fails, which cuts unplanned downtime.
Industry 4.0 and cybersecurity. Connecting machinery through the Industrial Internet of Things (IIoT) gives better control and flexibility, but it also exposes control systems to cyber risk. Standards such as IEC 62443 exist for securing industrial automation systems.
Next Steps for Your Industrial Operations
Industrial processes and automation systems together form the foundation of modern manufacturing. To get more from industrial process automation, start by looking at where PLCs, IoT integration and data analytics could improve your own processes.
If you need guidance, explore our industrial process solutions or contact the Greenpeg team to discuss your operations.