Digitalization in Process Engineering: Trends at POWTECH TECHNOPHARM

Networked sensors, AI algorithms, and automated bulk solids handling are transforming process engineering. This article explains which digitalization trends currently offer the strongest leverage and which exhibitors at POWTECH TECHNOPHARM 2026 are bringing concrete solutions for plant operators and planners to Nuremberg.

Written by Marius Schaub

Automatic filling head in a filling station that directs a fine stream of light-colored powder into a single open sack; reduced, blurred industrial background. — Automated powder and bulk solids handling is no longer a vision of the future in process engineering, but already a reality – for example in the form of automatic filling heads that dose powders precisely into bags.

Digitalization and automation have evolved in the process industries from ‘nice to have’ to central levers of competitiveness. Especially in process engineering, with its often complex, continuous and safety‑critical operations, new solutions open up numerous levers for higher productivity, stable product quality, improved raw‑material utilization, lower energy consumption, and a more effective use of scarce skilled labor.

Today, networked sensors deliver real‑time data from silos, reactors, mixers and conveying lines, which can be aggregated in control systems or IIoT platforms. On this data basis, algorithms, AI applications and modern automation systems optimize processes and make it possible to operate plants in a predictive and increasingly autonomous way – from bulk solids handling all the way to secondary packaging.

Trends at POWTECH TECHNOPHARM

The extent to which these trends are shaping process engineering is demonstrated by POWTECH TECHNOPHARM, which will once again bring the international community together in Nuremberg from 29 September to 1 October 2026. The trade fair is the gateway to the European market for technologies for processing powders, granules and bulk solids as well as handling liquids – including analysis, measuring instruments, control technology, automation and digitalization.

Particular focus is on trends such as networked sensor technology and IIoT, data‑driven and AI‑supported process optimization, automated powder and bulk solids handling, predictive maintenance and condition monitoring, as well as energy and resource management. Exhibitors at POWTECH TECHNOPHARM demonstrate their innovations directly in front of their target audience of plant operators, planners, equipment suppliers and engineering partners – often with live demonstrations and hands‑on best‑practice examples.

Digitalization is more than the sum of its parts

Digitalization in process engineering is not happening through a single technological leap, but through a series of interlocking developments. Networked sensor technology and IIoT first create the data foundation on which analytical and AI‑based tools can optimize processes and automation solutions can increasingly take over dosing, conveying and packaging.

In parallel, concepts such as predictive maintenance and condition monitoring are being established to safeguard the availability of critical assets, while energy and resource‑management solutions help operators keep overall plant efficiency in view.

AI-generated image in which a person in protective clothing supports a rock fragment. In the right part of the image several industrial measuring instruments, some with displays. — Measurement devices for industrial applications, such as those from Vega, have long been networked. Modern sensor technology, however, goes far beyond simply connecting to a central control system.

Industry 4.0: Networked sensor technology & IIoT

Networked sensor technology and IIoT are the starting point of any digitalization initiative. Modern instruments continuously measure level, point level, pressure and other process variables, communicate via standardized interfaces and become the “eyes and ears” of the plant control system. For process engineering, this means that operators can monitor levels, flow rates and critical states in silos, mixing vessels or conveying lines in real time, supervise limit values automatically via control systems and intervene from the control room or even remotely – an important step toward more transparent and safer processes.

One exhibitor who makes this development tangible is VEGA (booth 9‑348), which will be showcasing modern sensor technology for bulk solids and powder applications at POWTECH TECHNOPHARM. VEGA presents level, point‑level and pressure sensors, including radar solutions for demanding bulk solids applications that can be seamlessly integrated into common control‑system and IIoT environments.

Data analytics & AI‑based process optimization

Once processes are sufficiently instrumented, the key question becomes how to make meaningful use of the flood of information. This is where data analytics and AI‑based optimization come into play. In process engineering, AI algorithms can continuously evaluate dosing profiles, screening operations, filling processes or filtration, identify patterns and propose optimized settings in order to increase throughput, accuracy and energy efficiency.

A prominent example is HAVER & BOECKER (booth 7A‑519), which will present bulk‑handling and packaging solutions, filtration methods and AI‑based processes under the heading Artificial Intelligence & Robotics (AIR) at POWTECH TECHNOPHARM 2026. Together with its associated technology brands, the company will demonstrate live how image processing, robotics and data‑driven algorithms interact to fill, package and inspect bulk materials more precisely.

CAD rendering of a robotic system inside a safety cell that pallets bulk material in bags. — AIR systems from Haver & Boecker can intelligently optimize production processes. One example is Amicus Smart Cell, a robotic system that automatically removes empty bags from the pallet, hands them over to the filling machine and finally pallets the filled bags.

Automated powder and bulk solids handling

Automated powder and bulk solids handling directly addresses real‑world challenges: stringent hygiene and safety requirements, complex formulations and growing documentation obligations. Automated systems take over conveying, dosing and mixing of raw materials, reduce manual interventions and dust emissions, and at the same time enable precise, reproducible recipe management with lower error rates and higher process stability.

As a specialist in raw‑material automation and logistics, AZO (booth 7‑806) offers a broad portfolio for this purpose: plant engineering, bulk‑material logistics and its own control and automation technology for food, pharmaceuticals, cosmetics, chemicals and plastics. At POWTECH TECHNOPHARM, AZO will demonstrate what automated handling of major and minor ingredients as well as the integration of micro‑ and trace components into the process looks like – including solutions for connecting to control systems and data‑based optimization of material flows.

Industrial display shows key data on maintenance intervals for a machinery fleet, indicating when the next service date is due. — With a supervisory controller such as AERsmart from Aerzen, blowers and compressors are intelligently networked in order to increase their efficiency.

Predictive maintenance & condition monitoring

As automation increases, so does dependence on the availability of key assets such as blowers, compressors, fans or conveying equipment. This is where predictive maintenance comes in: instead of reacting only when faults occur, condition‑monitoring systems capture vibration and process data, detect deviations at an early stage and help plan maintenance activities in good time before unplanned downtime can occur.

AERZEN (booth 9‑420) will show at POWTECH TECHNOPHARM 2026 what this looks like in practice. The company will present process air and compressed‑air solutions that are combined with digital systems for condition monitoring and energy optimization. The exhibitor will also showcase software solutions that support efficiency gains and predictive maintenance for blower and compressor applications.

Energy and resource management through automation

In view of high energy costs and climate targets, the question of the energy and resource consumption of processes is moving ever more into the spotlight. Digital energy and resource‑management systems record consumption along the process chain, identify inefficient operating points and enable operators to implement measures to reduce power demand, compressed‑air consumption and material losses on a data‑driven basis.

A practical example is R + B Filter (booth 7A‑708), which supplies pleated filter elements and solutions for air and dust filtration and thus makes a direct contribution to energy‑efficient, low‑emission process engineering. At POWTECH TECHNOPHARM, the company will demonstrate how modern dust‑collection systems, through optimized filter elements and adapted control strategies, reduce compressed‑air requirements, keep air in the plant clean and at the same time minimize product losses.

Digitalization in process engineering is progressing continuously

In addition to core trends, further topics are evolving that are driving digitalization in process engineering: MES systems, digital quality monitoring or flexible automation modules for existing plants. They often act as the connecting layer between field instrumentation, automation and business systems and make it possible to look at entire plants digitally instead of just individual units.

Digitalization and automation have long since become strategic levers for process engineering – from networked sensors and AI‑based process optimization to automated bulk solids handling, predictive maintenance and energy and resource management.

Plant operators, planners, equipment suppliers and engineering partners who want to make their processes more efficient, stable and powerful will find a broad range of solutions and practical examples at POWTECH TECHNOPHARM 2026 to help them plan the next steps in their digitalization projects.

Further information and exhibitor/product search:
https://www.powtech-technopharm.com/en/exhibitors-products

Interested in this topic? Then come to POWTECH TECHNOPHARM and experience this and many other topics live at the trade fair. Secure your ticket here using the following code: PTTP26Insights.

Author

Marius Schaub