FEATURES: Control systems + automation Energy management + energy efficiency Safety of plant, equipment + people
Point-level measurement: Proven technology for energy applications
Medium and low voltage, Ex certified, AC and DC motors, transformers, generators, alternators and ancillary power generation equipment up to 373 MVA. ELECTRICAL SERVICES Full range of rotating machinery mechanical services. Machine shop capabilities including dynamic balancing up to 32 tons, large machining up to 40 tons, micro welding and hydraulic presses up to 1000 tons. MECHANICAL SERVICES Breakdown repairs, removal, re-installation, on-site testing, dynamic balancing, alignment, vibration analysis, root cause analysis, condition monitoring, preventative and predictive maintenance, motor management programmes and maintenance contracts. 24 HOUR ON-SITE SERVICES Reliability improvements/enhancements, efficiency improvements, performance upgrades and root cause analyses. CUSTOMISED ELECTRICAL AND MECHANICAL DESIGN YOUR 24/7 SERVICE PARTNER Repairs, maintenance and customised manufacture of all electrical and mechanical rotating machines.
+27 (0) 11 607 1700 | support@mandc.co.za 53 Hospital Street, Cleveland 2094, JHB www.mandc.co.za
COMMENT
FEATURES: Control systems + automation Energy management + energy efficiency Safety of plant, equipment + people
Getting to grips with a crisis E very now and again it seems to become quite evident that we live in a mad world, doesn’t it?
Point-level measurement: Proven technology for energy applications
problem at all. The problem was the decline in the energy availability factor, implying that, over the years, less and less energy was available to drive the economy. Even as we built new power stations (which were delayed by a significant period), the increase in generation capacity was obliterated by the decline in the energy availability factor. Sad. This trend seems to have been reversed. It was, however, an absolute crisis. And this was a crisis that saw some remarkable things happen. Industry, and even private individuals, took the opportunity – driven by necessity – to install their own energy sources. There was too a relaxation in the policy environment to make this possible. Remarkable what a crisis can do – and it does leave one wondering if there may have been a less disruptive method of driving users towards ‘cleaner’ off grid technologies. I am certain that, had the utility continued providing the energy needs of the country, we would never have seen the incredible growth in solar and wind technologies that we have seen. The progress has been spectacular. There is a catch – with so much of the load now off grid, who will continue to fund the utility? And, no matter what, will it remain a sustainable entity? Maybe that will present another crisis? Never waste a crisis.
In the energy sector, point level measurement plays a critical role in plant safety and equipment protection. Continuous measurement provides process visibility, and point level detection
Geopolitics rears its head and seems to have ripple effects no matter where one looks. This also does suggest that power is such a rare gift for any nation or any person that it really needs to be entrusted to those who appreciate the fact. To some extent, here, at the southernmost tip of a continent, we sit and watch what goes on. To some extent we feel out of control. We do face an international crisis – and it is possible that, as a nation, we have not quite come to grips with that. My mind immediately reverts to the old saying: never waste a crisis. This is an often- used phrase (or variations of it) and it has been variously attributed, but I understand it generally to be ascribed to Winston Churchill who clearly did face a crisis or two. I will not comment on what we should do as a country to capitalise on the emerging crisis, save to say we really do need to try a bit harder. What I would like to do is reflect on our capacity to deal with our own (generally self- inflicted) crises – and the obvious one relates to energy. We faced a bulk energy crisis, and we have emerged on the other side of it in a better position – although I recognise quite a few counter-views that do have merit. But think about this: the national utility has made significant improvements in the Energy Availability Factor – getting it to 69% by the end of last year. This is, of course, still way below the levels of the early part of this century. There was once a narrative that the trouble the utility faced was the need to deliver more energy than in the past – but that was not the
delivers decisive action. (Read more on page 3.)
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APRIL 2026 Electricity + Control
1
CONTENTS
FEATURES
CONTROL SYSTEMS + AUTOMATION 4 Towards AI-driven process automation Kobus Vermeulen, Schneider Electric 6 Building resilient food supply chains in Southern Africa Lourens Pieterse, Bühler Southern Africa 7 Products + services ENERGY MANAGEMENT + ENERGY EFFICIENCY 12 Tracking energy efficiency progress globally International Energy Agency 14 Grid modernisation as a catalyst for SA’s industrial future Sim Khuluse, SAPVIA 15 Understanding harmonic profiles John Mitchell, CP Automation 16 Expert O&M in embedded energy generation Dane Links and Hanno Mostert, SPS . 18 Battery energy storage systems in the energy transition Pervin Gurie, WEG 17 Products + services SAFETY OF PLANT, EQUIPMENT + PEOPLE 19 Fibre-optic cabling for safety critical systems in mining Ian Loudon, Omniflex 20 GMP is decided not in audits but in everyday production Minebea Intec 22 Behind most mine incidents Arjen de Bruin, OIM Consulting 23 Products + services
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12
19
REGULARS
1 Comment
Getting to grips with a crisis
20
3 Cover article
Point level measurement in the energy sector
28 Reskilling, upskilling + training Aligning workforce capabilities with national water priorities Renewable energy opens careers for SA youth 30 Engineering the future Electrifying boilers to decarbonise energy 32 Write @ the back SA does not lack plans but delivery systems
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2 Electricity + Control APRIL 2026
Cover article
Point level measurement in the energy sector: Reliable switching for critical applications
FEATURES: Control systems + automation Energy management + energy efficiency Safety of plant, equipment + people
I n the energy sector, point level measurement plays a critical role in plant safety and equipment protection. While continuous measurement provides process visibility, point level detection delivers decisive action, preventing overfills, protecting pumps from dry running and ensuring reliable operation under demanding conditions. Across Sub-Saharan Africa’s energy landscape, from coal-fired power plants to renewable and emerging energy technologies, vibrating point level switches have proven to be a robust and dependable solution. Their product-independent operation, millimetre-precise switching accuracy and minimal maintenance requirements make them well suited to harsh industrial environments. Liquid applications: safety and process reliability The VEGASWING 63 vibrating level switch provides reliable point level detection for liquids with densities between 0.5 and 2.5 g/cm³. A key advantage is its tube extension, which allows the switching point to be positioned up to six metres from the installation location, offering flexibility in tanks and vessels where the ideal switching point cannot be achieved with a compact sensor. The instrument delivers consistent switching performance regardless of mounting position or medium properties, making it suitable for overfill protection in fuel and oil storage tanks, providing dry-run protection for pumps and empty/full vessel detection in auxiliary systems. The product-independent switching point eliminates the need for calibration with the process medium, reducing commissioning time and maintenance effort. For high-temperature and high-pressure applications, the VEGASWING 66 offers dependable point level detection in demanding process environments. Designed for use with liquids with densities from 0.42 to 2.5 g/cm³, it is available in a compact version or with a tube extension of up to three metres. Typical applications include
six metres enables precise switching point placement in silos, bunkers and transfer points. Its smooth, seamless rod design prevents
Point-level measurement: Proven technology for energy applications
material build-up, ensuring reliable operation in coal handling and biomass-related applications. Medium-independent setup and low maintenance requirements make this switch well suited for use in harsh, dust-laden environments. Powdered and fine-grained solids For powdered and fine-grained bulk solids such as fly ash and fine coal dust, the VEGAWAVE 63 vibrating fork level switch delivers reliable detection for materials with densities as low as 8 g/l. The robust tuning fork ensures stable switching performance, even with adhesive or abrasive products. With tube extensions up to six metres, the switching point can be positioned precisely to suit process requirements. Proven technology for energy applications Vibrating point level switches are widely used in the energy sector due to their reliability, simplicity and durability. Key benefits include millimetre-accurate switching, independence from product properties, fast commissioning and low maintenance. As the energy sector across Sub-Saharan Africa continues to evolve, dependable point level detection remains essential for operational safety and continuity. VEGA’s VEGASWING, VEGAVIB and VEGAWAVE instruments provide robust, application-driven solutions for both liquid and bulk solid processes throughout the energy value chain.
For more information contact VEGA Controls (Pty) Ltd. Tel: +27 (0)11 795 3249
Email: info.za@vega.com Website: www.vega.com
steam generators, condensate tanks and auxiliary vessels in thermal power plants. Continuous sensor self-monitoring and robust construction ensure reliable operation and enhanced safety, even under extreme conditions. Bulk solids: coal and ash handling applications The VEGAVIB 63 vibrating rod level switch is designed for use with granular and coarse-grained bulk solids with densities as low as 20 g/l. A tube extension of up to
VEGA’s vibrating point level switches have proven to be robust and dependable in coal-fired power plants as well as in new renewables applications.
APRIL 2026 Electricity + Control
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Control systems + automation
WRITE @ THE BACK
Towards AI-driven process automation As process industries advance towards an AI-driven future, Kobus Vermeulen, Direct Sales Executive, Process Automation at Schneider Electric, outlines four major trends that are set to redefine automation strategies through 2026: hyper automation, AI-first automation, low code/no code platforms, and real-time process intelligence.
Kobus Vermeulen, Schneider Electric.
F rom unified platforms that blend AI, machine learning, and robotic process automation (RPA) for end-to-end optimisation, to AI-driven self-healing operations, ‘citizen developer tools’, and predictive process intelligence, these trends provide a view into how process automation will evolve. Hyper automation: a new era of integration Leading industrial organisations are increasingly incorporating hyper automation into their strategies. This integration of AI, machine learning, and RPA into unified platforms provides end- to-end process optimisation, particularly in complex industrial environments. Platforms like AVEVA Unified Operations Centre and UiPath Hyper automation enable organisations to gain greater visibility and control across operational technology (OT), information technology (IT), and business workflows. The trend towards agentic AI and autonomous operations is also gaining ground. AI agents embedded in industrial software can take over automated tasks such as dashboard creation, alarm management, and predictive analytics. Cloud-native copilots, such as Microsoft Azure Copilot, facilitate lifecycle governance and optimisation of automation agents, creating an environment where real-time decision-making and closed-loop optimisation are achievable. Furthermore, improved process intelligence is enabling organisations to identify bottlenecks more effectively, generating automation-ready workflows through process mining and modelling tools. Integrating these tools with manufacturing
execution systems (MES), computerised maintenance management systems (CMMS), and asset performance management (APM) systems, organisations can achieve real-time execution and create feedback loops that inform continuous improvement. The results are notable: documented benefits include up to a 27% reduction in downtime, 10 to 30% cost savings, and significant gains from predictive maintenance and enterprise visibility. AI-first automation: autonomous operations come into view The shift towards AI-first automation signals a change in how organisations are approaching operational processes. Through 2026, businesses will increasingly rely on AI systems not only to automate tasks but also to predict potential issues and respond automatically. In predicting issues, AI-driven platforms will analyse real-time and historical data from IT systems, OT assets, and IoT sensors, allowing organisations to anticipate failures and intervene proactively. Automated responses and closed-loop control mechanisms enabled by AI will further facilitate operational continuity. We expect to see businesses implementing AI-driven platforms that ensure dynamic load balancing, auto-scaling, and real- time parameter adjustments without human intervention, thus minimising mean time to repair (MTTR). The implementation of self-healing infrastructure will elevate AI-first automation to a new level. AIOps and agentic AI will empower IT and OT systems to self-repair, autonomously
Process intelligence is evolving to become integral to AI-driven automation strategies.
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Control systems + automation
Process intelligence: evolving to meet future demands Process intelligence is evolving beyond process mining to become integral to AI-driven strategies. Organisations will increasingly leverage real-time analytics from various operational and business systems, moving from historical data analysis to predictive insights. This will enable businesses to ask – and answer – not only, ‘What happened?’ but also, ‘What will happen?’ and ‘What should we do next?’ AI-powered analytics will allow leaders to anticipate equipment failures, detect process deviations, and provide actionable recommendations. Further, using digital twins, organisations can simulate ‘what-if’ scenarios, so they can make the best decisions. This proactive approach helps reduce waste, improves operational efficiency, and can support sustainability goals, making process intelligence a strategic advantage for the future. The road ahead: aligning with evolving trends These four trends, hyper automation, AI-first automation, low-code/no- code platforms, and process intelligence, will clearly shape the broader landscape of process automation in 2026 and going forward. Organisations that harness these innovations will improve operational efficiencies and enhance decision-making and agility, to ensure they remain competitive in an increasingly dynamic market. The convergence of the technologies can create a cohesive ecosystem where automation is faster, smarter and more responsive to real-time needs. Embracing these trends, businesses can empower their workforce, streamline processes, and achieve sustainability goals. We anticipate a renaissance in process automation that drives significant value creation and sets new standards for operational excellence.
addressing issues: restarting failing services, for example, patching vulnerabilities, or resolving configuration drift. For manufacturing operations, this means adopting technologies that can automatically recover and optimise processes, enhancing overall efficiency. Low code/no code platforms: empowering citizen developers As organisations move towards the new automation environment, low-code/no-code (LCNC) platforms will play an essential role, empowering non-technical users to develop and deploy automation without deep coding knowledge. The tools are now seen as fundamental components in digital transformation frameworks, particularly for industries like manufacturing, utilities, and mining. Providing visual drag-and-drop interfaces and pre-built templates, LCNC platforms will enable business users from diverse departments – such as operations, HR, finance, and marketing – to automate repetitive tasks and prototype applications independently. The democratisation of development opens the door for citizen developers to innovate, bridging IT skills gaps and reducing reliance on specialist developers. Gartner forecasts that by 2026, over 80% of new digital initiatives will leverage LCNC platforms, with a substantial portion of automation drivers emerging from user departments rather than traditional IT settings. This shift will accelerate digital transformation and support a culture of continuous improvement through rapid iteration and scaling.
For more information visit: www.se.com
Control systems + automation : Products + services
Smarter batch automation
Enhancements include manual step acknowledgment, an improved user interface and permissions, and simplified reuse of recipe components for faster development. Built-in campaign tools help maximise throughput and efficiency, and compliance features, such as full electronic recordkeeping, support ISA-88, FDA 21 CFR Part 11, and ISPE GAMP-5 standards. Valmet FlexBatch is now available for Valmet DNAe customers and it remains fully compatible with the Valmet D3 Distributed Control System. Valmet provides a clear upgrade path from previous Valmet FlexBatch versions to make new advanced features available for existing Valmet FlexBatch customers.
Valmet has expanded its automation solutions portfolio for the process industries with the release of Valmet FlexBatch®8, the latest version of its advanced batch automation and recipe management software. Valmet FlexBatch was originally developed for the Valmet D3 automation system and with the newest version, it is fully integrated with Valmet DNAe and Valmet D3 automation solutions. Valmet FlexBatch delivers advanced batch automation and recipe management, empowering fast, safe, and ISA-88-compliant batch production. The software enables operators to manage batch processes using intuitive drag-and-drop tools, without the need for programming. Using Valmet FlexBatch integrated with Valmet DNAe, operators can take full advantage of a modern web-based user interface for batch operations. “The new release, with the possibility to integrate with Valmet DNAe, is a significant step forward in expanding our automation portfolio in the process industries, especially in the chemical industry where our customers need to produce batches with consistent quality, quickly and cost-efficiently with secured traceability,” says Tiina Stenvik, Director, Process Industries, Energy and Process Systems Automation, Valmet. Valmet FlexBatch introduces capabilities that simplify batch processing and improve operational efficiency. Operators can monitor current and historical batch results directly within the Valmet DNAe interface, which provides real-time visibility and control.
For more information visit: www.valmet.com
Valmet FlexBatch introduces capabilities that simplify batch processing and improve operational efficiency.
APRIL 2026 Electricity + Control
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Control systems + automation
WRITE @ THE BACK
Building resilient food supply chains in Southern Africa Across Southern Africa, food supply chains are operating under increasing strain. Climate volatility, infrastructure constraints, energy instability, rising input costs, and exposure to global trade disruptions are everyday operating pressures. Lourens Pieterse, Head of Sales, Bühler Southern Africa, says in this context, resilience has become just as important as efficiency in ensuring long-term food security.
Lourens Pieterse, Bühler Southern Africa.
R eliable equipment, smart automation, real-time monitoring, strong customer support, and skilled local talent all play a role in building a more sustainable and dependable food value chain. For decades, food systems have been built to maximise efficiency, scale, and affordability. Today, climate-related disruptions, energy shocks, and market volatility are exposing the structural fragilities of that model, which assumed relatively stable climate conditions, predictable energy supplies, and reliable global trade. To remain resilient and competitive, the systems need to be redesigned. Grain systems – from agriculture through silo storage to processing – are at the core of this shift, as they shape how shocks propagate – or are contained – across the food system. In volatile environments, milling and food processing operations constitute critical infrastructure for food security. Converting raw agricultural commodities into safe, storable, and transportable food, producers in the food system ensure reliable food availability. Effective processing reduces post-harvest losses, extends shelf life, and supports consistent quality, even when agricultural production or weather patterns are unpredictable. Strengthening resilience across the milling value chain requires a system-wide approach. Modern, reliable equipment is essential. Predictive monitoring to prevent unplanned downtime, improved storage to safeguard grain quality, and robust logistics are equally critical, as
they contribute to operational stability. Investing in local expertise through continuous training and closer collaboration among farmers, processors, and other supply chain partners is another key factor. Together, these measures enable mills to maintain safe, consistent food production where there may be external disruption. Reliable equipment, automation and process optimisation Innovation only strengthens resilience if it is adapted to local realities. In regions facing persistent energy and infrastructure constraints, solutions need to be practical, robust, and designed for operating conditions on the ground. In such environments energy-efficient equipment helps sustain output during power disruptions, and modular and scalable processing systems allow capacity to be adjusted as conditions change. Robust storage infrastructure protects raw materials and finished products, and digital tools built to function with limited connectivity ensure technology enhances resilience rather than introducing new vulnerabilities. Energy efficiency, automation, and process optimisation are directly linked to food security outcomes. Bühler’s energy- efficient grinding and processing technologies, combined with automated process control and digital monitoring solutions, help reduce operating costs and energy demand while maintaining consistent throughput. Advanced automation and quality control systems support food safety and product consistency. Data-driven optimisation of workflows and predictive maintenance services minimise waste and unplanned downtime. Together, these solutions help ensure that food production remains stable and reliable in challenging operating environments. Sustainability is central Sustainability is a prerequisite for stable food production. Reducing waste, improving energy efficiency, and ensuring safe, high-quality output directly affect the availability and affordability of food. When combined with local training and technical support, sustainable solutions strengthen food systems and contribute to long-term food security. Critical aspects to ensure food safety and reduce waste are sometimes overlooked in discussions about resilience, yet they are fundamental to building a stable and nutritious food system. Across Africa, Bühler has supported food ‘fortification’ initiatives in countries such as Nigeria, Kenya, Tanzania, and Ethiopia, working with millers, governments, and development partners to integrate precise dosing, mixing, and quality control solutions into maize and wheat milling. These efforts help staple foods deliver essential micronutrients at scale.
As well as the value of reliable equipment and automated processing, Bühler recognises the importance of collaboration across the wider agricultural ecosystem.
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Control systems + automation
Close to customers Local presence and regional expertise are key in turning these principles into practice. This includes customer service, maintenance, and close collaboration with local teams. Understanding local challenges, responding quickly to operational issues, and tailoring solutions to specific conditions all depend on local teams in the region. Being close to customers depends on people. Local presence and regional expertise are built by investing in talent – developing the skills needed to operate, maintain, and improve complex food-processing systems continuously under local conditions. This is why Bühler places strong emphasis on training and upskilling local teams, ensuring technical expertise, operational know-how, and service capabilities are available where they are needed. Building talent in the regions it serves, Bühler strengthens customer support, accelerates problem-solving, and thus contributes to reinforcing the long-term resilience of local food systems. One example of this approach is the African Milling School in Nairobi, Kenya. Since 2015, the African Milling School has trained more than 1 600 millers from over 30 countries across Africa, the Middle East, and India. Collaboration across the wider ecosystem Collaboration across the wider ecosystem is equally important. Partnerships between industry, government, and communities bring together expertise, resources, and coordination. Such collaboration enables better planning, shared infrastructure, and joint initiatives that reduce risk and improve efficiency, contributing to a consistent and safe food supply across Southern Africa. Looking ahead, there are clear practical steps that can be taken now to prepare for future disruption. Investment in modern, reliable equipment, digital monitoring, and energy-
efficient technologies will be critical. Strengthening storage and logistics, developing local skills, and fostering closer collaboration across the food system will further enhance resilience. By taking these steps, the region’s food and milling industries can build supply chains that are better equipped to withstand climate, market, and infrastructure challenges, supporting long-term food security for Southern Africa. Bühler teams are ready to support this transition with local expertise and long-term partnerships across the region. Partnerships involving industry, government, and communities bring together expertise, resources, and coordination – helping to reduce risk and improve efficiency.
For more information visit: www.buhlergroup.com
Control systems + automation : Products + services
Automated tracking and management of IT assets
Automation shifts IT asset management from reactive to a proactive capability. Continuous discovery replaces periodic stock takes. Exceptions are flagged immediately. Visibility improves financial control and audit readiness. V-Track embeds automation into daily operations through real time dashboards, usage visibility, and structured lifecycle tracking. Security exposure decreases because assets remain accountable from deployment to retirement. Nagiah avers that manual management does not save money. It defers cost until it appears in audit findings, compliance penalties, or forced write offs. Automation is today the baseline for responsible governance. Organisations that delay will fall behind, and at a.cost, she says. Reference [1] https://www.mordorintelligence.com/industry-reports/it-asset- management-market
Manual IT asset management is often described as flexible. However, Valene Nagiah, V-Track Head Asset Tracking and Management cautions that in modern hybrid environments, it is a growing liability. Organisations relying on spreadsheets and periodic reconciliations are not cautious. They are operating without real visibility, she says. Research reported by Mordor Intelligence [1] links automation directly to improved control. As IT estates expand across cloud platforms and remote users, manual tracking fails under complexity. The weakness is not only inaccuracy. It is delay. By the time information is verified, audits, renewals, or security incidents are already under way. Studies consistently show that poor asset visibility leads to overspending on licences and avoidable audit penalties. Without real-time reconciliation of ownership and usage, organisations pay for what they cannot validate.
For more information visit: www.vtrack.io
APRIL 2026 Electricity + Control
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Control systems + automation : Products + services
Using AI in automating water management
anticipate maintenance conditions for equipment. Similar technologies have expanded to help water managers forecast demand, such as consumption peaks. They can also optimise energy consumption by adjusting operations based on demand. Advanced metering infrastructure Smart meters have improved the performance and efficiency of water distribution networks, using digital technologies to gauge consumption and feed reliable data into water planning systems. Advanced metering infrastructure (AMI) is the next step in that journey. AMI
In many applications, the right combination of data and algorithms can produce marked improvements in efficiency, speed, and oversight. While some, even most water utilities already use digital monitoring and analytics to manage operations, artificial intelligence can build on these capabilities by identifying patterns in large datasets, enabling predictive insights, and supporting more informed decision- making. Recognising this, around 15% of large water utilities around the world are already using artificial intelligence. This is set to reach 30% by 2026, according to the Xylem Water Technology Trends 2025 report. By 2035, it is expected that three-quarters of water utilities will use some form of AI. With aging infrastructure, climate variability, and rising water demand placing increasing pressure on water systems, utilities are seeking more resilient and adaptive ways to manage operations. Data-driven and AI-enabled tools are emerging as part of this broader digital transformation in the water sector. Experts have good reason to be optimistic about AI adoption in the sector. Already, digital water management systems are producing excellent results. For example, Yorkshire Water Services in the UK, which uses Xylem Vue digital services, last year reported a reduction in visible leaks by 57% as well as a reduction in annual distribution main repairs by 30%. Similar digital and AI-driven capabilities are also being used in industrial water and wastewater operations, where predictive monitoring and process optimisation help improve compliance, reliability, and resource efficiency. Such outcomes show the hidden capacity at every water management site, says Chetan Mistry, Strategy and Marketing Manager at Xylem Africa, WSS. “Water distribution and treatment sites produce far more data than they use. But that data gets neglected because of capacity. It would take an enormous amount of time to organise and study the data for patterns and insights. Digital and AI systems are solving those problems. Digital systems record and share accurate and reliable data, which AI systems use to produce planning information, automation, and other improvements, fast.” Water management sites utilise smart data and AI services in several ways. Real-time process adjustment Water treatment is at its best when the system can maintain consistency. This is a laborious task because water flows keep changing. Intelligent water systems add intelligence that adjusts processes such as reagent dosing and treatment line control in real time. Site operators define specific scenarios that automatically adjust operations using information from external technologies such as water management applications and business intelligence systems. Predictive demand and optimisation AI systems predict conditions to manage demand and optimisation. Predictive maintenance systems rely on predictive analytics and AI-driven models, which use performance data and systems such as digital twins to
Chetan Mistry, Strategy and Marketing Manager at Xylem Africa, WSS.
performs remote reading and integrates and processes information into AI systems, significantly reducing information intervals towards almost real-time monitoring and feedback. Decision support systems Water utilities are using decision support systems (DSS) to inform real-time medium- and long-term planning and management. DSS tools use AI to analyse large datasets and information from different disciplines, including data from hydrological and meteorological stations, expert knowledge, and local inputs. Such analyses can model different situations, from simulating water bodies to predicting usage patterns. While these and other data-driven improvements seem attractive, utility and infrastructure managers are not always sure where to start. Successful deployment depends on data quality, integration with existing infrastructure, and organisational readiness. Deploying digitisation can become complicated, which is why leading water technology OEMs like Xylem develop and maintain extensive software platforms designed to meet water utility challenges. The real advantage of using data-driven water management platforms is not just in the new features. It enables utilities to leverage information they already have: “Data that does nothing only takes up space. But data made useful through cloud-based management software opens additional dimensions for planning and predictive actions such as maintenance.”
For more information visit: www.xylem.com/en-za/
Although data-driven improvements seem attractive, Xylem notes that successful deployment in water management utilities depends on data quality, integration with existing infrastructure, and organisational readiness.
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Control systems + automation : Products + services
Championing sustainable, scalable industrialisation across Africa
Ensuring product quality in motion plastics Motion plastics manufacturer igus has expanded its testing facilities to a total test laboratory footprint of more than 5 500 m² of dedicated research space in order to accommodate its increasing product portfolio and enable continuous improvement of its product quality. The newly enlarged test laboratory combines several testing areas for energy chains, highly flexible chainflex cables, iglidur plain bearings, drylin linear technology, low-cost automation components and igus:bike applications. New developments are expected to enable deeper and broader evaluation of product performance before any products are released to customers. Ian Hewat of igus South Africa says, “igus has expanded its test laboratory to support faster innovation cycles and more comprehensive real-world testing scenarios. This means customers will benefit with greater confidence that the components they use will perform reliably in their specific applications under the most demanding conditions. “A feature of the expanded facility is the new 1 500 m² test area, adding to existing dedicated outdoor and indoor test Johan Nieuwenhuizen, Sales Director and Co-CEO says, “As Africa moves towards the next phase of industrialisation, reliable, affordable and locally supported technology is essential. The Adroit Supervisory and Human Machine Interface software was built in Africa for African conditions, and our mission is to ensure every customer can modernise at a sustainable pace without sacrificing existing investments.” South African industrial automation software leader Adroit Technologies reaffirms its commitment to accelerating Africa’s industrial growth by providing resilient, affordable, and future- ready digital solutions for utilities, manufacturing, and process industries. With more than three decades of experience and over 30 000 licences deployed across six continents, the company continues to build technologies shaped by the realities of African operations. Adroit Technologies maintains prices in line with African markets and all licences, services, and support are based on South African currency. This way African customers avoid exposure to volatile foreign exchange rates. It makes advanced SCADA, IIoT, MES, mobility, and digital transformation solutions accessible to organisations that need predictability and cost-efficiency. The company’s technology integrates seamlessly with new and legacy infrastructure, enabling gradual modernisation without disruptive system replacement. Thus, Adroit Technologies plays a role in sustainable and inclusive industrial development. Its software supports critical sectors including mining, manufacturing, water management, food processing, energy, and public utilities. In addition to technology, the company provides comprehensive skills development through structured training, top-tier telephonic support, certified system integrators across the continent, and a dedicated Digital Services Division specialising in cloud, IIoT and AI. It serves customers not only as a software supplier but as a long-term partner.
The company’s flexible approach reduces the barriers to digital adoption: it offers licensing based on real data points, unlimited internal I/O, and concurrent client licensing. Owning its intellectual property and maintaining rand-based pricing, Adroit Technologies claims that it delivers one of the lowest total costs of ownership (TCOs) on the continent. The company’s platforms directly support ongoing industrialisation across the African continent by assisting economic transformation through sustainability, regional integration, and innovation. Its solutions help reduce energy
Johan Nieuwenhuizen, Sales Director and Co-CEO, Adroit Technologies.
consumption, enable multi-site visibility across borders, and introduce Industry 4.0 capabilities without requiring infrastructure replacement. Adroit Technologies also bridges the OT/IT divide with native OPC UA and MQTT integration (Open-Platform Communications Unified Architecture and Message Queuing Telemetry Transport, the standard messaging protocol for machine-to-machine communication in IoT applications), secure mobility, cloud-ready edge technologies, and enterprise-friendly APIs (Application Programming interfaces). With strong engineering support and specialised training, African organisations can confidently maintain integrated digital ecosystems for long-term efficiency. “By extending rather than replacing existing systems, we enable industries in Africa to modernise without operational disruption. This strategy, combined with robust local support and accessible pricing, continues to position Adroit Technologies as a trusted partner in the continent’s industrial transformation,” says Nieuwenhuizen.
For more information visit: https://adroitscada.com/
spaces. The testing environments simulate real operating conditions, including outdoor weather exposure, extreme temperatures down to -40°C, cleanroom- comparable environments and customer- specific application trials,” Hewat says. He adds that the test laboratory runs more than 15 000 individual tests across over 742 test stations every year. These include endurance runs, multi-axis stress tests and application-specific cycles such as long travel simulations for energy
At the igus test facility all tests are conducted according to international standards.
chains and dynamic loads for bearings. The extensive data generated in the expanded facility feeds into igus’s online tools, including the service life calculator, product finders, CAD configurators and predictive maintenance tools. As a result, the tools help engineers and procurement professionals more accurately define the right components for their projects.
For more information visit: www.igus.co.za
APRIL 2026 Electricity + Control
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Control systems + automation : Products + services
Siemens advances its control and protection portfolio
Siemens Smart Infrastructure has announced significant advances in its portfolio of industrial control and protection devices. The company is expanding the functionalities of its semiconductor- based SENTRON Electronic Circuit Protection Device (ECPD) and introducing the SIRIUS 3RW5 -Z R11 refurbished soft starter, its first product designed according to circular economy principles. These developments will help customers in industrial environments enhance electrical safety, increase system availability, and improve their environmental footprint. As the world´s first of its kind, Siemens’ SENTRON ECPD was introduced to the market in 2024. It provides up to 1 000 times faster secure electronic switching to minimise short-circuit energy and protect systems. It offers 10+ configurable functionalities in a single device, reducing space in the distribution board by 80% and allowing for flexible, software-based parameterisation. The single-phase version of the ultra-fast SENTRON ECPD is planned to follow soon and will be available as a standalone product featuring
Left: The single-phase version of the SENTRON ECPD with RCM, right: a model of the future three-phase version of the SENTRON ECPD.
starter at Light & Building 2026. Described as the first circular soft starter, the product is created through a controlled refurbishment process of used soft starters, resulting in a reduction of CO₂ emissions of typically up to 50% compared to a new device through reduced resource consumption. The process is transparently documented with Environmental Product Declarations (EPDs). During refurbishment, used devices are thoroughly tested. Critical components are replaced, and all functions are tested to meet new device quality standards. The result is a soft starter technically equivalent to a new one, fully compatible in installation, parameterisation, and functionality, allowing seamless integration. Devices have CE certification, with CCC, UL/CSA, and ATEX certifications pending. “The new offering underscores Siemens’ commitment to innovation, sustainability, and resource efficiency in industrial applications. With our SIRIUS 3RW5 -Z R11 refurbished soft starter, customers get a refurbished product that performs as well as a new one, providing a dependable and environmentally friendly option,” Matthé added. SIRIUS 3RW5 -Z R11 refurbished soft starters are circular by design. Their modularity allows easy dismantling and repair, with identifiable components for efficient refurbishment. As a smart device, the soft starter provides usage and condition data from its first life cycle, enabling targeted remanufacturing for a second. The ID Link, a unique QR code, ensures traceability for both first and second life products. This ID Link, and a data architecture currently under development, using Asset Administration Shell (AAS) and Distributed Ledger Technology (DLT:IOTA), paves the way for a Digital Product Passport (DPP) in line with the EU’s Ecodesign for Sustainable Products Regulation (ESPR), ensuring transparency and audit-proof lifecycle information.
an integrated Residual Current Monitoring (RCM) function. RCM allows for continuous monitoring of residual currents, enabling the early detection of faults in electrical circuits without interrupting operations. This ensures 24/7 system uptime and protects valuable equipment. This functionality is particularly suitable for systems with high safety relevance and/or high system availability standards like data centres and various industrial applications. In addition, the RCM function can replace complex, recurring inspections, simplifying maintenance procedures. To address high-voltage systems (400 V/32 A/50 Hz), Siemens also plans to introduce a three-phase version of the SENTRON ECPD. Offering the same functionalities, its scope of use will include infrastructure and industrial applications, like conveyor belts, elevators, heat pumps, air conditioning systems, safe and stable power distribution for events or UPS (uninterrupted power supply) systems. “Siemens is leveraging advanced semiconductor technology to redefine industry standards in circuit protection,” said Andreas
Matthé, CEO Electrical Products at Siemens Smart Infrastructure. “Our SENTRON ECPD offers unparalleled speed, precision, and a compact design that ensures maximum operational uptime and protection for our customers’ infrastructure.” Driving sustainability through circularity in industry Siemens launched the SIRIUS 3RW5 -Z R11 refurbished soft
For more information visit: www.siemens.com
SIRIUS 3RW5 -Z R11 refurbished soft starter
10 Electricity + Control APRIL 2026
Control systems + automation : Products + services
Partnership drives opportunity and economic growth in Limpopo Ecovado, an emerging agri‑processing company founded by local entrepreneur Hulisani Mudau, recently launched its new avocado oil processing plant in partnership with Alfa Laval Middle East, South and East Africa. The project supports economic development in the u Vhembe District community in Limpopo, South Africa.
Ecovado was established by Mudau who recognised the region’s untapped potential in an abundance of avocados – which he saw could help address the limited economic opportunities in the area. The company was created to stimulate local development through job creation, fruit‑for‑cash initiatives, and long‑term agricultural sustainability. To help the company realise its vision, Alfa Laval facilitated funding through the Swedish export credit agency, EKN, enabling Ecovado to build and equip an avocado oil processing plant with a 100% Alfa Laval processing line. This world‑class technology enables Ecovado to produce high‑quality avocado oil, most of which is destined for export markets. Additionally, Alfa Laval donated funds to purchase avocado seedlings for small‑scale farmers in the surrounding communities. This initiative aims to expand local avocado production, ensuring long‑term supply for the plant and creating new income streams for households. Rooted in community impact “This project represents what sustainable industrial development should look like, world‑class technology enabling local entrepreneurship, job creation, and long‑term community development. We are proud to support Ecovado in transforming the abundant harvest of avocado farming in Venda into real economic opportunity. This project captures Alfa Laval’s purpose, ‘Pioneering positive impact’” said Bongani Twala, General Manager of Alfa Laval South and East Africa. For Ecovado, the partnership marks a business milestone and is a catalyst for regional transformation.
Product tasting at the launch.
Hulasani Mudau, Managing Director of Ecovado, highlighted the significance of the initiative saying, “This project was born from a desire to change the economic landscape of my home community. With Alfa Laval’s support, we have been able to build a facility that processes avocado oil and at the same time creates livelihoods. The funding, equipment, and seedlings donation have empowered us to grow an industry that belongs to the people of Venda.” A model for rural industry The Ecovado plant is fully operational, employing local residents and sourcing fruit directly from small‑scale growers. As production scales, the company aims to expand its network of community suppliers and increase export volumes, positioning Venda as a competitive player in the global avocado oil market. The partnership between Ecovado and Alfa Laval demonstrates how strategic investment, local leadership, and advanced technology can build economic potential in underserved regions.
For more information visit: www.alfalaval.co.za
Emerging agri-processing company Ecovado recently launched its avocado oil processing facility in partnership with Alfa Laval.
APRIL 2026 Electricity + Control
11
Energy management + energy efficiency
Tracking energy efficiency progress globally In its latest annual analysis on global energy efficiency developments, Energy Efficiency 2025 , the International Energy Agency (IEA) reveals recent trends in energy intensity and demand, investment, employment and policy. The report, released in November 2025, provides sector-specific analysis on industry, buildings, appliances and transport and explores system-wide themes such as emissions reductions, energy security, affordability and competitiveness.
demand growth has accelerated since 2019, while the average annual rate of industrial energy intensity improvement fell to under 0.5% over that same period, compared to almost 2% in the last decade. This global shift towards more intensive energy use in industry is offsetting gains made in other sectors and is weighing down overall efficiency progress. Policy is lagging technology Policies have lagged technology progress, leaving significant savings on the table. Many appliances being sold today are only half as efficient as the best available models. As technologies have become more efficient in recent years, energy efficiency standards have not progressed at the same pace. For
Although there is significant scope to progress energy efficiency, IEA analysis shows that efficiency gains since 2010 have had a major impact in reducing today’s greenhouse gas emissions and energy efficiency remains one of the key drivers to lower emissions in future.
T he Executive summary of the report outlines key findings, as below. Global energy efficiency progress was set to improve by 1.8% in 2025, up from around 1% in 2024. Preliminary estimates indicate several key regions are showing signs of stronger progress compared to their average since 2019. For example, energy intensity progress in 2025 was estimated to be over 3% in the People’s Republic of China (hereafter ‘China’) and over 4% in India, well above their averages in the years since 2019. In the United States and the European Union (EU), on the other hand, progress in 2025 was set to fall below 1% after several years of stronger performance following the energy crisis. Yet the world remains off track to achieve the COP28 ambition for 2030. In 2023, nearly 200 governments agreed at COP28 in Dubai to work together to collectively double the global average annual rate of energy efficiency improvements by 2030. However, global energy efficiency progress – measured by the rate of change in primary energy intensity – has fallen to 1.3% per year on average since 2019. This is just over half its longer-term average of around 2% per year in the period 2010 to 2019, and well below the COP28 target of a 4% annual improvement by 2030. Four key trends are holding back faster progress. Slow progress in the industrial sector Around two-thirds of global final energy demand growth since 2019 has been concentrated in industry, a sector where energy intensity progress has slowed sharply. Industrial energy
example, the efficiency of best-in-class lightbulbs doubled in the last 15 years, yet minimum performance standards have gone up by only 30%. Rapidly rising cooling demand Increased access to air conditioners has pushed up cooling- related electricity demand. Higher living standards have allowed more people to afford cooling technologies such as air conditioners, especially in emerging economies. Energy for space cooling has seen the fastest growth of any end-use in buildings since 2000, growing over 4% per year. However, this increased demand has been met with equipment that is not highly efficient, further straining energy systems at a time of rapid growth. If every air conditioner bought since 2019 had been the most efficient available, the world could have avoided electricity demand growth equivalent to the demand growth from data centres over the same period. System inefficiencies Electricity demand growth has outpaced renewable supply leading to an overall increase in less efficient fossil fuel generation. Electricity demand has grown two to three times faster than overall energy demand since 2019. In some regions, this rising demand has led to greater use of inefficient generation sources, placing upward pressure on primary energy demand and slowing progress in improving energy intensity. The report further notes that investments in advancing
12 Electricity + Control APRIL 2026
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