Process engineering in transition: greater flexibility, lower energy consumption and safe production

Modular process engineering is constantly breaking into new areas. Modular plants can be designed quickly, delivery times are reduced, and maintenance and the supply of spare parts are usually simplified. This also applies to individual components and machines.

Trend 1: Modular systems simplify configuration

Some suppliers already offer modular rotary valve systems. For POWTECH TECHNOPHARM 2026, Köllemann (Booth Number 9-228c) has announced its new generation of rotary valves as a modular system. Based on a standardised basic rotary valve, various drive and equipment variants can be configured. Just as with a new car, predefined packages can be selected. This results in tailor-made solutions at reduced costs, such as high-temperature, wear-resistant or ATEX versions.

This principle also applies to screening machines. IFE Aufbereitungstechnik (Booth Number 9-563) will be presenting the VARIOframe screening machine, which, thanks to its modular frame, can handle a wide range of tasks. Screen decks and frame segments can be configured individually. Various screen linings and multi-decks (e.g. a protective deck) are also available. The screening dynamics are infinitely adjustable during operation, ensuring particularly high flexibility and excellent screening quality. A fundamental vibration prevents blockages, even with demanding materials such as cable scrap, waste glass, compost and other fine, damp and sticky materials.

Trend 3: reducing the CO₂ footprint in filtration …

A number of new developments are driving down operating and energy costs. The Flexpro filter system from Herding (Booth Number 7-726) achieves this through a combination of sophisticated design, flow rate control and digitalisation. Advanced sintered lamella filters, the newly designed Herding Pro filter element and intelligent air guidance reduce energy consumption without compromising performance. The CO₂ footprint is reduced by up to 25 per cent. The system ensures pure recovery without contamination, as well as exceptionally low pure gas values. It can be easily commissioned using the plug-and-play principle. Furthermore, it can be easily integrated into IoT and control systems via an OPC UA interface and features a digital twin (see also our latest technical article ‘Digitalisation in Process Engineering: Trends at POWTECH TECHNOPHARM’).

For particularly large air volumes, there is also the Herding Maxx series of large-scale filter systems, which is now also available with integrated explosion protection. The sintered lamellar filter used acts as a barrier to prevent dust from entering explosion-hazard zones. As a result, there is no dust-explosive atmosphere on the clean air side of the filter system. Furthermore, the system utilises a flameless and smoke-free pressure relief mechanism.

The dustar S60 cartridge filter systems from Indusa (participant in the VDMA Special Exhibition, Booth Number 7-776) also deliver long-term energy cost savings. They are designed to achieve a high separation efficiency with low pressure drop. To this end, conventional IE2 motors right through to modern IE4 or EC motors are used. With a range of filter media, virtually all dust applications (ceramics, metal, glass, etc.) are covered.

… and when heating with hybrid systems and electric elements

Systems powered by electricity also contribute to CO₂ reduction. Those who utilise low-cost industrial electricity when there is a surplus of PV power can also optimise their operating costs. Hybrid systems ensure that operations are not jeopardised even during periods of low sunlight and low wind. One example is the hybrid heating systems from Tecflam (Booth Number 9-548). They combine electric air heaters (E-HAG) and duct burners or indirect hot-air generators, offering maximum flexibility in the heating of process air and in energy management.

In contrast, the LiquiCore high-temperature screw heat exchanger from Köllemann (Booth Number 9-228c) operates entirely on electricity. It enables precise, efficient thermal treatment of bulk materials in a temperature range from approximately 145 °C to 650 °C. In the newly developed screw shaft, electric heating elements are embedded in a hermetically sealed core made of a low-melting-point metal. Once this metal has melted, it distributes the heat and ensures rapid, uniform heat transfer. As the system operates without thermal oil, there is no need for heaters, pumps or pipework. This results in compact, robust and high-performance solutions for demanding thermal processes, such as those in the recycling industry.

Trend 4: Contamination-free production across many industries

What has long been a must in the pharmaceutical industry (see the article ‘From the cleanroom to the zip fastener’) is also becoming increasingly important in other sectors: containment. Problematic fine dust particles are also found in the battery industry, in recycling and in the field of additive manufacturing. Employees must also be protected from certain active ingredients used in the food and cosmetics industries. Conversely, products such as baby formula must not be contaminated.

At this year’s POWTECH TECHNOPHARM, Dositech (Booth Number 7-892) is showcasing the AB-Cut system, a solution for the automatic feeding of storage hoppers. It combines bag detection, robot-assisted cutting and controlled emptying; manual handling is completely eliminated. The AI-supported system not only ensures contamination-free material supply and dust containment, but also full traceability.

At the end of the process chain, for example, solutions from Burgener (Booth Number 7-634) could be employed: the Swiss company offers the right filling technology for every type of container – from individual pouches to big bags. With integrated pressure control, sealing and cleaning technology, contamination-free filling can be achieved.

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