- 11/10/2025
- Article
- Automation & digitalization
Future technologies at POWTECH TECHNOPHARM – Part 1
Smart systems are real drivers in industry – and are often necessary to remain competitive. At POWTECH TECHNOPHARM 2025, numerous exhibitors presented a wide range of AI-supported approaches for better, more efficient production, both at their stands and in the forums. These ranged from automated powder handling and AR-supported pipeline planning to AI-optimised operation of energy storage systems.
Written by Dr. Ulla Reutner
‘Hardware’ such as bulk material conveyors, mixers and dosing devices seemingly dominated POWTECH TECHNOPHARM 2025. But those who took the time to look more closely encountered the ‘soft’ technologies that turn equipment and machines into future-proof solutions at every turn: AI, robotics and automation, to name a few, all of which make production future-proof. Some exhibitors also took the opportunity to present these solutions at one of the forums. The following three examples demonstrate the variety of approaches.
Augmented reality is revolutionising pipeline planning
It starts with plant design. The use of augmented reality is already a reality here. Two years ago, Tobias Werner and Heinrich Nickel from Jacob Rohrsysteme provided an early insight into the potential of AR in pipeline design at POWTECH. Their system has since been used by several test customers. Jacob produces around 580 km of pipes annually – and these are used in a wide variety of industries – from toothpaste manufacturing to muesli production, coffee roasting to wood pellet production. Werner says, "As things stand today, the planning process is extremely time-consuming and not much fun. But with the help of our augmented reality-supported application, things look very different. We want to revolutionise pipeline planning with augmented reality."
The previous process, from scanning an existing plant on site and creating a digital plan to the actual pipe planning on a computer using CAD software and the subsequent customer review to the creation of parts lists and finally ordering, is characterised by many interfaces, departments involved, as well as manual steps. This leads to inaccuracies and errors. ‘Typically, our customers used to order 15 per cent more than planned, especially in the area of elbows. This was to ensure that there would be no stoppages during the installation of the pipeline.’
In the middle of the exhibition hall, colleague Nickel, equipped with HoloLens 2 AR glasses, demonstrates how to do it more efficiently. With a few hand movements, he accesses the Jacob catalogue programme and virtually builds the installation from straight pipes, elbows, branches, etc. A flick of the finger moves pipes that would weigh 30 kilograms in reality. Viewers can follow what Nickel sees through his glasses live on the screen behind him as a complex structure gradually emerges. If a virtual collision threatens, Nickel immediately receives a warning and can decide whether the pipeline should still be constructed in this way because the obstacle is temporary and can be easily removed, or not.
Augmented reality is only part of the solution. The app created by Jacob generates and exports the drawing so that it can be processed further in almost any CAD programme. After approval by the customer, who can use the AR glasses for this purpose, the system generates a list of all planned components, including clamping rings and seals. The order can then be placed with just one click. “With our app, we combine several planning steps into one process, thereby speeding up planning considerably,” summarises Werner. The app is still in the prototype phase, and the company is looking for more test customers. In future, the application will be made available for download. This will enable numerous planners to benefit from it, such as the customer who had to install an additional air duct in a 1.2-metre-high false ceiling full of pipes. Thanks to Jacob's AR-based solution, this was a success.
Prospects for automated powder handling
High-tech solutions for the entire production process are also on display at POWTECH TECHNOPHARM. Thomas Eules from Sacchi provided a comprehensive overview of the possibilities that AI and robotics can offer in powder handling. He described the transition from the status quo in many production facilities, characterised by a large number of manual processes, to extensive automation and the outlook for Smart Factory 4.0. “At its core, it's about integrating the physical world into the digital world,” says Eules. He cites real-time data analysis with pattern recognition and centralised control, preventive maintenance, automated quality control and complete traceability as key elements. One of the challenges is the automatic adaptation to changing conditions.
“In the automotive sector, it is unthinkable that parts are still being carried from A to B. But in powder handling, bags are still being lugged around today,” says the expert, warning of high powder exposure and quality problems. The digital process begins as soon as the products are delivered and transported to production, for example through automatic identification via barcodes, QR codes or RFID tags, as well as AI-supported image processing that identifies bags and detects damaged containers. Digital integration into the warehouse management system eliminates paperwork and recording errors. Autonomous transport systems to the emptying station enable 24/7 operation. Pallets are reliably transported to the correct station, where robots empty the bags. 3D vision systems ensure safe gripping and precise positioning at the emptying point. Further pneumatic conveying of the powder prevents the introduction of germs or moisture.
Once the recipe has been processed, for example with the aid of mobile robots, what Eules summarises as ‘Smart Mix’ follows: mixing with the aid of AI-supported process control using integrated sensors for power consumption, torque, temperature, etc. AI software stops the process at the optimum mixing point, documents all parameters and ensures complete traceability. The smart process also encompasses the filling, packaging and palletising of the end product.
“At the heart of every Sacchi solution is a networked control system that integrates all components into a higher-level MES or ERP system, brings together the IoT infrastructure and encompasses AI optimisation, including predictive maintenance, process optimisation and energy management,” Eules summarises. For those looking to develop their existing production towards a smart factory, he recommends the following as a first step: ”Discover the robot in you! Take a look: for which manual tasks are there automated solutions? You'll be amazed at what's currently happening on the market.” In addition to autonomous mobile robots (AMR) and advanced AI analytics, he highlights digital twins in particular as future prospects in automated powder handling.“ In the future, we will map all powder handling processes completely virtually in order to simulate and optimise them in real time”, says Eules, looking ahead.
AI-supported multi-use optimisation of battery storage
Manufacturing industries are securing their future viability not only through smart manufacturing processes. Intelligence is also finding its way into energy supply. An increasing number of companies are turning to renewable energies to reduce their carbon footprint and lower energy costs. In this context, battery storage is becoming increasingly important, as it is being adopted by an ever-growing number of energy-intensive companies in view of rising, volatile electricity prices. Nicolàs Juhl, CEO of encentive, a start-up founded in 2020, explains how AI can help these systems pay for themselves particularly quickly. He distinguishes between single-use and multi-use optimisation. The latter is anything but trivial, as Juhl illustrates in his presentation. Artificial intelligence is the key.
Encentive knows how to take advantage of spot market electricity prices when batteries are charged and discharged intelligently. Widely fluctuating electricity prices, high during periods of low wind and low cloud cover, low when the sun is shining and the wind is blowing, will be the norm in the future. “The difference between the highest and lowest prices for electricity has almost quadrupled in the last five years,” says Juhl. Industrial companies should therefore consume renewable electricity when it is produced. A site manager, on the other hand, wants to consume electricity when production requires it. Juhl concludes: “So we have to control the systems in such a way that they consume electricity when it is cheapest. We also have to decouple using batteries that can store and release electricity.’
Juhl lists the goals that can be pursued through intelligent control of this system: from peak load capping and thus avoiding particularly high grid fees, to optimising the self-consumption of a company's own PV system, to purchasing electricity at the most favourable market prices. “If I want to try to take all of this into account when controlling the battery, I come to multi-use optimisation,” says Juhl, emphasising: “This brings the highest added value, but is also the most difficult to achieve.” This is because, in addition to the conditions resulting from production requirements, factors arising from battery operation must also be taken into account, such as high wear and tear from rapid charging and discharging and warranty conditions.
Some of these optimisation goals contradict each other. For example, purchasing large amounts of electricity at a very low price would lead to high grid fees. AI solutions for the multi-use optimisation of battery operation take all variables into account and make a decision – every second. This results in a charging and discharging cycle that considers consumption, generation and price forecasts. This differs from single-use optimisation, where the battery charges fully as long as there is surplus electricity available from the PV system, but is then full when the electricity price may even be negative on a sunny afternoon. And where the battery is discharged again in the evening when electricity is most expensive.
Juhl illustrates this with a real-life example: a customer who was able saved €31,000 a year in electricity costs with single-use optimisation decided to switch to multi-use optimisation. “By taking into account the forecast for grid fees, energy prices and the consumption of the systems, he was able to save over €100,000 by proactively charging and discharging the battery.” Refrigeration systems can also be optimised with this type of energy management platform. The customers of the young start-up encentive include companies from the food, paper and materials industries. The platform is aimed at anyone who values a stable power supply for their processes and wants to reduce costs. Battery storage systems and their intelligent control will make a major contribution to competitiveness in the future, especially in the target industries of POWTECH TECHNOPHARM.
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