FEATURES: Control systems + automation Renewable energy + industrial sustainability Measurement + instrumentation Transformers, substations + the grid
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.
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COMMENT
SA’s young scientists compete with the best A s I write this, I have just returned from the ‘far west’ of the planet having attended the Regeneron International Science and Engineering Fair (ISEF), a programme of the Society for Science and the Public in the USA. The ISEF is the largest pre-college science and engineering fair internationally, attracting well over 1 700 young scientists from across the world. They are judged based on the quality of their work presented at the fair.
Based on my observations, I would rate this year’s ISEF as having the highest overall standard I have ever seen at the fair. It is undeniable that the whole Covid pandemic aected basic education around the world – but it is clear to me that we are more than over that hiccup now. And it is heartening to see this. It means young scientists, and their educators, are right on top of the latest challenges, the latest technologies, and the latest tools to add value to research. And of course, AI is part of the deal. It is to be embraced, but to be used ethically and smartly, as it should be. I recall that when I was at school, we were allowed to use calculators… now, that may be obvious to some, but it was not a common trend back then. Many thought it was the worst possible thing that could be done. Well, we survived, and frankly had a far better education, pushing far more boundaries than folk limited to log books and counting on their fingers… While I was at the ISEF, I was reminded that I have been a Grand Awards judge there for 15 years now, and a Co-Chair for seven. Time flies when you are having fun, doesn’t it? It is my fervent view that the Eskom Expo for Young Scientists must continue to participate in this pinnacle event – and challenge our own basic education system to step up and reach the general standards that we know it is capable of – indeed, that we know it has to reach if, as a nation, we are going to hold our own on the planet! Our top performing learners are world class, of that there is no doubt, but we need to li£ everyone up to those levels. We have no time to waste, and we have no option!
Editor: Leigh Darroll Business Development Manager: Angela Devenish Design & Layout: Katlego Montsho Circulation: Karen Smith Technical Editorial Consultant: Ian Jandrell South Africa’s renewable energy sector continues to grow as the energy transition progresses and the country moves towards a liberalised, competitive, electricity market, placing new demands on the transmission grid.
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Although there are many special awards, made by groups and institutions interested in specific attributes of the competitor and their work – for instance, the award of a scholarship to study at a university close to the youngster’s hometown – the really significant awards are the Grand Awards. Grand Awards judges are selected from industry, research, academia – and from across all nations. Their task is to identify the work deserving gold, silver, bronze and 4th awards in each category – where typically a category will have one gold award, and possibly three silver awards and so on. It is a remarkably competitive environment. In South Africa, the Eskom Expo for Young Scientists is the local fair ailiated to the ISEF, and each year selected South African youngsters have the chance to compete against the very best in the world at ISEF. No amount of speaking and sharing can ever compensate for actually being there, being part of the fair, and engaging with other young people who share your own passions. In my view, what happens at ISEF is that bright young people discover that they are part of a growing and vibrant international group of like-minded youngsters who can only see a better world driven by Science, Technology, Engineering and Mathematics. And so it should be! These are our people! They are the real ‘rock stars’ of the future, these are the youngsters who will build our collective future.
Publisher: Wilhelm du Plessis Managing Director: Karen Grant
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CROSS PLATFORM CONTENT INTEGRATION: * Electricity+Control Magazine * Online Edition * Weekly e-Newsletter * Website* LinkedIn
Electricity+Control is supported by
Ian Jandrell PrEng IntPE(SA), BSc(Eng) GDE PhD, FSAAE FSAIEE SMIEEE
The views expressed in this publication are not necessarily those of the publisher, the editor, SAAEs, SAEE, CESA or the Copper Development Association Africa
JUNE 2026 Electricity + Control
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CONTENTS
FEATURES
CONTROL SYSTEMS + AUTOMATION 4 Ensuring precision in automotive ‘shrinker’ machines SEW-EURODRIVE 5 Technology convergence is rede ning competitive advantage World Economic Forum 6 Ef ciency and traceability in feed production Adroit Technologies 8 Smart milling – ef ciency, consistency and competitiveness Bühler Southern Africa 9 Products + services News from Beckhoff, and Leibinger RENEWABLE ENERGY + INDUSTRIAL SUSTAINABILITY 10 Diverse energy sources meet growing global demand International Energy Agency 11 24/7 renewables outcompete fossil fuels on costs International Renewable Energy Agency 12 EPC selection is critical for new energy projects Claude Peters, RenEnergy 14 Countering rising energy costs and carbon taxes Anja Visagie, Sustainable Power Solutions 16 Tracking South Africa’s energy market transition Shailin Moodley, EXSA 18 Global Wind Report 2026 Global Wind Energy Council 19 Products + services News from 7Second Solar, Mulilo, Richards Bay Minerals MEASUREMENT + INSTRUMENTATION 21 Measurement as the foundation for governance NMISA and NRCS 22 Products + services News from Endress+Hauser, GEMÛ, ifm, and Vepac Electronic s TRANSFORMERS, SUBSTATIONS + THE GRID 24 Powering South Africa’s industrial revival Mervyn Naidoo, ACTOM 25 Digital substations – modernising the grid Mohamed Hosseiny, Hitachi Energy Africa 26 AI enabled smart grids and the clean energy shift Global Data 27 Products + services News from ABB, Doble, LH Marthinusen, Schneider Electric, Trafo Power Solutions
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REGULARS
1 Comment
SA’s young scientists compete with the best
3 Diary dates
Upcoming events 30 Reskilling, upskilling + training
Volunteering can be a step towards career progress 31 Write @ the back Middle East tensions chokehold global helium supply
2 Electricity + Control JUNE 2026
Diary dates
AEF returns to Cape Town this year
National Energy Development Institute (SANEDI), Department of Mineral & Petroleum Resources, and the Central Energy Fund (CEF). As governments, utilities and investors focus increasingly on industrial growth, energy security and infrastructure delivery, South Africa’s presence at aef 2026 reflects the country’s central role in Africa’s energy and industrial landscape. More widely, Africa’s transmission sector, now seen to be entering a new phase, will be in focus. Projects once viewed as too complex or too dependent on public funding are moving into execution – with private capital increasingly entering the grid. As governments accelerate industrialisation strategies, transmission is increasingly becoming the critical infrastructure challenge. In South Africa, NTCSA’s Transmission Development Plan aims to deliver 14 500 km of new transmission infrastructure over the next decade as the country looks to unlock renewable capacity, strengthen grid resilience and support long-term industrial growth. At aef 2026, senior leaders from across the public and private sectors, including local and international financial development institutions, will debate what comes next for transmission investment, open access and regional power.
At a time when governments and investors are focused on industrial growth, grid expansion, energy security and regional competitiveness, South Africa remains one of the continent’s most closely watched energy markets – from electricity reform and generation capacity to infrastructure delivery, battery storage, nuclear energy and industrial innovation. The Africa Energy Forum (aef) 2026, to be held at the Cape Town International Convention Centre from 16 to 19 June, welcomes a strong South African public sector delegation, bringing together ministers, regulators, utilities and state agencies. Minister of Electricity and Energy Dr Kgosientsho Ramokgopa will lead the South African delegation and will host key conversations, steering the continent-wide industrialisation and production hub discussions. Deputy Minister, Samantha Graham-Maré, will also be participating and she will join Dan Marokane, GCE of Eskom, and others, in the opening session to explore investment, partnerships, and opportunities in South Africa. Further public sector institutions to be represented include the National Energy Regulator of South Africa (NERSA), the IPP Oice, the Nuclear Energy Corporation of South Africa (NECSA), the South African
For more information visit: https://info.energynet.co.uk
Made in Africa, for Africa
and investors to tackle challenges and unlock opportunities relating to manufacturing. The conference programme is geared to generate dynamic discussions and networking opportunities to shape Africa’s manufacturing future, opening routes to expand markets, adopt advanced technologies, and shape industrial policy. The programme is structured to cover a spectrum of key current issues including: Localisation & industrial strategy AI, automation & Industry 5.0 Sustainability & Green manufacturing Market access & Trade expansion – leveraging AfCFTA and regional trade agreements Investment & incentives - understanding the financial support pro- grammes available, and building public-private partnerships Workforce & skills development.
Manufacturing Indaba is set to take place on 14 and 15 July at the Sandton Convention Centre in Johannesburg. Africa is home to 15% of the world’s population and abundant resources, yet it contributes only around 3% to global manufacturing. Manufacturing is fundamental to economic growth, driving job creation, trade, and industrial development across the continent. It oers a pathway to self-suiciency and creating new markets. Yet, Africa’s manufacturing sector struggles with import dependency, underinvestment, trade barriers, and a skills shortage. Strengthening local production, innovation, and industrial collaboration is key to building a resilient, competitive sector. Manufacturing Indaba is an established annual event dedicated to driving Africa’s reindustrialisation, supporting local manufacturing, connecting leaders, and empowering businesses to grow. The event brings together industry leaders, policymakers, Industrial innovations at Electra Mining Africa 2026 Emerging innovations are transforming the South African mining, manufacturing, industrial and automation sectors and driving the deployment of advanced technologies and solutions across operations. Innovations in mechanisation, automation and digitisation are improving safety and productivity in mines, production facilities, industrial plants and warehouses. To deliver real value, these technologies must be cost- eective and designed to address practical, people-centred industry challenges. The current growth in automation is impacting local industries positively – facilitating investment in innovation, data analytics and skills development, and helping to develop local competitiveness and export potential as local African solutions are adapted to be exported regionally and globally. South African engineers are leaders in innovation and technology development. Many of these innovations and newly
For more information visit: https://manufacturingindaba.co.za/
automated systems will be on display at Electra Mining Africa 2026, the largest trade-show of its kind in Southern Africa, set to take place at Nasrec in Johannesburg in September. For example, automation so£ware for CNC specific user interfaces that simulate part machining using real-time data will be on show, as will new developments in intelligent, digitally-enabled power solutions for modern, mission-critical facilities. Specialised industrial sensing and monitoring technologies that ensure the reliability of data feeding into industrial systems will also be on display – demonstrating digital speed, position and condition monitoring solutions designed for use in demanding industrial environments. These and many other new technologies from more than 1 000 exhibitors will be on display across dierent zones at Electra Mining Africa, which this year will run from 7 to 11 September.
For more information visit: www.electramining.co.za
JUNE 2026 Electricity + Control
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Control systems + automation WRITE @ THE BACK
Ensuring precision in automotive ‘shrinker’ machines
Jendamark Automation’s innovative catalytic converter ‘shrinker’ machine, designed and built in South Africa for export worldwide, uses SEW-EURODRIVE’s advanced servo-geared units and motion control soware for its precision operation. The highly automated assembly cell integrates multiple machines, robots and laser measurement systems.
the segments close in, collapsing the can evenly around the monolith.”
Servo motor systems Driving that motion are two powerful SEW-EURODRIVE servo motor systems, each connected to precision roller screws that pull the ring from both sides. Synchronising the drives is critical. “If one side is pulled just a few millimetres more than the other, this will damage the very expensive roller screws,” Naidoo explains. “This is where we rely on SEW-EURODRIVE’s technology; the drives and controllers keep the two motors synchronised to within very fine tolerances, even at the high speeds we need to hit our 30-second cycle times.” The speed at which Jendamark Automation’s shrinker operates is one of its critical advantages, Naidoo emphasises, and this has been achieved through its innovative tool changer. He notes that flexibility is particularly important in converter production for commercial vehicles as variants change every few hours. Traditionally, each change required a lengthy manual tool change, which would mean two to three hours of downtime. “This is why we developed an automatic tool change system for the shrinker,” he says. “We have two cartridges outside the machine, one of which is preloaded with the next set of 16 segments. When the operator hits ‘tool change’ the machine ejects the old set, inserts the new one and locks everything down – all automatically – in about 45 seconds.” That innovation, also powered by SEW-EURODRIVE servo drives, has transformed productivity. “We have reduced tool changing times significantly, giving our customers more production time per shi£, allowing them to produce around 80 additional parts,” he says. “With two or three tool changes a day, the gains are massive.” The entire catalytic converter assembly cell can contain up to 30 SEW-EURODRIVE servo drives, powering and synchronising various machines – from laser measuring systems to robotic handlers. Behind the scenes, Jendamark’s proprietary Variant Manager so£ware orchestrates these movements. “Every part coming down the line is slightly dierent, so every 30 seconds a new set of parameters – such as diameters, spring loads and positions – is sent to the drives,” Naidoo says. “There are no fixed positions; it is completely dynamic, adapting in real time.” Parallel to this performance, he adds, is an equivalent focus on reliability as customers require minimal downtime to ensure their processes and products remain viable. He notes that a USA customer, Cummins (through its acquisition of Faurecia’s USA factory), has been running Jendamark’s shrinker for almost six years, during which time it has produced over three million catalytic converters.
SEW- EURODRIVE servo gear units and motion control software ensure dynamic
B ased in Gqeberha in the Eastern Cape, Jendamark Automation is a specialist in advanced automated assembly systems for powertrains, catalytic converters, hydrogen technologies and various automotive components. About 95% of Jendamark’s locally produced systems are exported to markets in Europe, India and the USA. Yanesh Naidoo, Executive Innovations Director at Jendamark Automation, explains the shrinking machine – or ‘shrinker’. “This is a core component within our catalytic converter assembly cell. The cell is a highly automated production environment in which machines, robots and laser measurement systems operate in coordination.” The process begins with the core of a catalytic converter – a ceramic ‘brick’ or monolith, coated with precious metals such as platinum and palladium, that converts exhaust gases into less harmful emissions. This brick is wrapped in a thick spring- like insulation mat and inserted into an outer casing (or can) of stainless steel. Naidoo says that in this process, there are many variable factors to consider. “Because the ceramic monolith is extruded and baked, its diameter can vary slightly – by two or three millimetres in a passenger vehicle converter and up to ten millimetres in a truck converter. This makes the size of every monolith slightly dierent.” To secure the monolith inside the casing with the right spring load, the casing itself has to be adapted. This is the key function of the shrinking machine – to reshape the stainless steel casing to the exact diameter required for each brick and mat combination. Shrinking stainless steel to tolerances of 50 microns requires enormous force and control, which the shrinker achieves by closing a set of heavy tapered segments around the can. “For a passenger vehicle converter, we use twelve segments, and for a commercial vehicle converter, which is larger, we use sixteen,” Naidoo says. “We pull a massive steel ring back over those segments and as the ring moves
precision in Jendamark Automation’s catalytic converter shrinker machine.
Continued on page 5
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Control systems + automation
Technology convergence is redefining competitive advantage A recently released World Economic Forum report indicates that competitive advantage is shiing from owning key technologies to combining them across data, people and ecosystems. It suggests that the next wave of competitive advantage will come not from individual breakthrough technologies but from the ability to combine and scale multiple technologies across entire operating systems. A s artificial intelligence, robotics, advanced materials, spatial
“Technology conver- gence has evolved from a technical discussion into a strategic leadership man- date with direct operational impact,” said Aiman Ezzat, CEO of Capgemini Group. “Competitive advantage
computing and next-generation energy systems mature si- multaneously, the organisations and countries moving fast- est to apply these technologies together in intelligent systems are already pulling ahead. The report, Technology Convergence: The New Logic for Compet- itive Advantage , produced in collaboration with Capgemini, draws on cross-industry research and real-world case studies in 12 sectors, identifying recurring patterns, including the blending of mature and experimental technologies and the blurring of industry boundaries, that determine whether convergence scales or stalls. “Breakthrough technologies are advancing rapidly, and value is created when they are applied together,” said Cathy Li, Head of the Centre for AI Excellence and Member of the Executive Committee, World Economic Forum. “The real dierentiator is not who owns the most advanced tools, but who can combine them across systems and applications at scale.” As advanced technologies scale, the main bottlenecks to com- petitive advantage are no longer time or materials but how well organisations connect digital tools with physical operations. This is already playing out across sectors and geographies. From factory floors and power grids to research labs and healthcare, converging technologies are reshaping how systems perform worldwide. In the United Kingdom, surgical robots are extending clinicians’ capacity and preserving workflow continuity across care teams. In China, automated labs are linking robotics, AI and data platforms to accelerate discovery as they coordinate workflows across research networks.
increasingly depends on an organisation’s ability to integrate technologies, teams, partners and op- erating processes into co- herent systems that deliver value at scale. Leaders who master orchestration, not just adoption, are translating convergence into sustained performance and growth.” Jeremy Jurgens, Managing Director of the World Economic Forum added: “This shi£ has implications for companies as well as for national growth strategies and industrial policy. Economies that align talent, infra- structure, data and policy will be better positioned to capture the benefits of converging technologies in a fast-shi£ing global landscape.” The report is part of the World Economic Forum’s Technology Con- vergence Initiative, launched in 2024, and builds on the first edition published in 2025. It draws on two years of cross-industry research, including interviews with experts, workshops and case studies.
The advantage of combining technologies carries implications for companies as well as national growth strategies and industrial policy.
For more information visit: www.weforum.org
accurate positioning and torque this machine needs,” Steyn says. “The challenge was to deliver very high torque while maintaining precise synchronisation and feedback at high speeds.” He says it is easier to be accurate when machinery is moving slowly, but it becomes much more challenging in the context of high-speed machines like this one. SEW-EURODRIVE’s control architecture ensures that every motion – from the synchronised pulling of the ring to the positioning of the auto-tool change mechanism – is tracked and verified before the next cycle begins. “There is a great deal of feedback between the drive and the upper level controller,” Steyn explains. “The system scans the input data – the product types and can sizes – and adjusts torque and position in real time. It is the brain and the muscle working together.” Naidoo highlights the value of SEW-EURODRIVE’s integrated unit – the motor, gearbox and drive – which is already matched for torque and speed.
Continued from page 4
“Apart from greasing the screws, there has been no major maintenance required and no drive failures at all,” he says. “That is a testament to the robustness of our overall design and the reliability of SEW-EURODRIVE equipment.” The customer was so impressed that it decided to standardise globally on Jendamark’s machines. “They had two other suppliers’ machines next to ours on the same line,” Naidoo says. “Now they’re replacing those with Jendamark machines, because of reliability and consistency of quality.” Advanced motion control Phillip Steyn, Branch Manager at SEW-EURODRIVE in Gqeberha, says the project exemplifies how advanced motion control systems enable complex automation. “Our MOVIAXIS multi-axis servo system, combined with our eicient servo motors and dynamic gearboxes, provides the
For more information visit: www.sew-eurodrive.co.za
JUNE 2026 Electricity + Control
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Control systems + automation
Efficiency and traceability in feed production As South Africa’s poultry industry continues to evolve in response to rising demand, cost pressures, and stringent quality requirements, producers are increasingly turning to advanced automation systems to optimise operations. At Sovereign Foods, one of the country’s leading poultry suppliers, a large-scale automation project has delivered significant gains in eiciency, traceability, and operational control. W orking in partnership with proudly South African industrial so£ware leader Adroit Technologies, Sovereign implemented the Mitsubishi Adroit Process Suite (MAPS) across a key feed production facility, easy to see where faults are, and operators can quickly understand what is happening in the plant.” This usability extends beyond operations into maintenance and troubleshooting. “It is not just about running the plant, it is also about maintaining it,” adds Hewitt. “The system makes fault-finding and troubleshooting very straightforward, which reduces downtime and helps us keep the plant running eiciently.”
creating a scalable, integrated system capable of supporting current operations and future expansion. Dominik Zabiegaj, MAPS Project Engineer, says, “The system is fully integrated, from materials and recipes through to batching and reporting. Everything is built into the platform, which means no separate systems or add-ons are needed.” Integrated SCADA and PLC layers “From a project perspective, one of the biggest advantages of the MAPS suite is the reduction in engineering time,” says Bradley Campbell, National Sales Manager. “Because the SCADA and PLC layers are integrated, the engineering eort is, in eect, halved, complexity is reduced, and the quality of the system is improved. That translates directly into cost savings for the customer, along with the benefit of strong local support.” Starting in 2019, the project was implemented in phases, allowing Sovereign to align the system rollout with broader operational goals and capital planning. By the time Senior Production Manager Neil Hewitt joined the business in late 2020, the system had been installed but was not yet fully operational. “I came on board to manage the mechanical and electrical aspects of the project,” Hewitt explains. “I was involved in the commissioning phase and understanding how the system interacts with the plant. From there, it was about refining the system to ensure it works optimally from an operator and maintenance perspective.” Reduced engineering complexity The integrated SCADA and PLC functionality on the MAPS platform in a single environment significantly reduces
Processing live operational data One of the most powerful aspects of the MAPS system is its ability to capture and process live operational data. This provides Sovereign with deeper insight into performance, energy usage, and production eiciency. “The system allows us to gather a significant amount of live data that we can use to continually improve our processes,” says Hewitt. “We can extract it into reports, track eiciencies, and monitor electricity usage. We have only scratched the surface of what is possible.” This data-driven approach enables more informed decision-making and supports continuous improvement across the operation. Traceability supports quality control In a highly regulated industry like animal feed production, traceability is critical. The MAPS system provides full visibility across the production process, from raw material intake to final product delivery. “Traceability is one of the most important aspects for us,” Hewitt adds. “We can track materials from the point they enter the plant, through batching and processing, to the final product delivered to farms.” This level of detail supports quality control and risk management. “If there ever is an issue, we can trace exactly what was used, where it came from and where it went, within minutes. A further benefit is that if something is out of specification, the system will stop the process immediately. That allows us to address issues in real time, rather than a£er the fact.” Operational consistency Technically, the MAPS platform delivers a high degree of integration and standardisation, simplifying initial deployment and future modifications. This standardisation also benefits long-term maintenance and scalability. “By standardising on MAPS, any contractor can come into the plant and quickly understand the system,” Zabiegaj highlights. “It makes fault- finding easier and ensures consistency across the operation.” Additionally, the system architecture enables expansion without significant re-engineering. “It is based on a client-server model, so if the plant grows, the user can simply upgrade licences and add more I/Os or PLCs. There is no need to redesign the system,” says Zabiegaj. Sovereign designed the system with future expansion in mind, ensuring additional capacity and functionality could be added with minimal disruption. “We took a phased approach and built in the capability for expansion from the start,” says Hewitt. “That means we can add new equipment and functionality without major changes to the infrastructure.” This flexibility has already been demonstrated, with additional plant capacity introduced in 2023. “It is
Bradley Campbell, Adroit Technologies.
Neil Hewitt, Sovereign Foods.
engineering complexity. It also meets a further key requirement for Sovereign – ensuring that the system is intuitive and accessible for operators at all levels. According to Hewitt,
this has been one of the standout successes of the project. “For the end- user, the system is far more user-friendly than others I have worked with,” he says. “The graphics are clear, it is
Integrated automation enhances visibility and control across poultry operations.
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Control systems + automation
Delivering automation projects For Campbell, this reflects a broader shi£ in how automation projects are delivered. “It is not just about supplying a product. It is about building a long-term partnership,” he says. “As the customer’s needs evolve, the system evolves with them.” Today, the MAPS implementation is delivering clear benefits across Sovereign’s operations, including improved eiciency, reduced downtime, and enhanced product quality. “From my perspective, the system is reliable, user-friendly and continues to improve as we build on it,” Hewitt says. “It has made a real dierence to how we operate.” As the poultry sector continues to face increasing pressure to optimise performance and maintain strict quality standards, integrated automation solutions such as MAPS are set to play an increasingly important role in enabling sustainable, scalable growth.
largely a matter of programming and commissioning, rather than extensive new hardware,” says Hewitt.
Advanced automation features The system also oers advanced automation features that can enhance eiciency over time. “There are capabilities around automated routing, prioritisation and production optimisation that we haven’t made full use of yet,” notes Hewitt. “But the functionality is there, and it gives us a clear path for future improvements.” Beyond the technology, the success of the project has been underpinned by strong collaboration between Sovereign and Adroit Technologies. “There was a lot of communication throughout the process, especially during commissioning,” says Hewitt. “Any challenges were addressed quickly, and the support has remained strong.”
For more information visit: www.adroitscada.com
Control systems + automation: Products + services
2DJET™ – A new coding class for product packaging
With GS1 standards gaining momentum globally, the strategic importance of 2D codes is clear. How to implement them in real production environments is what needs to be resolved – where speed, uptime, cost-eiciency and maximum flexibility across a variety of packaging materials still define success. And this is where theory and practice have o£en diverged. A new approach LEIBINGER is taking the next step in industrial coding. As an innovation leader in CIJ, the company brings decades of expertise in high-speed high-reliability coding. It also oers extensive ink know-how, built on the development and in-house manufacturing of a broad ink portfolio. With 2DJET, LEIBINGER is introducing a new coding class developed specifically for the next generation of packaging requirements. The new system features a continuous ink supply designed for uninterrupted production. It delivers clear codes at up to 300 dpi and printing speeds of up to 120 m/min, with the capability to print QR codes in up to 33 x 33 modules. Built on LEIBINGER’s deep understanding of industrial coding in real production environments, this newly developed approach redefines what manufacturers can expect from 2D coding. For a wide range of packaging For packaging manufacturers, this new coding class has been designed for print quality and to meet practical production needs. As a touchless printing technology, 2DJET brings with it the core advantages that have made CIJ successful in industrial environments. It can be used across various packaging materials and for dierent product shapes and surface conditions – from flat to curved, and from smooth to more challenging surfaces. With a throw distance of 8 mm, the compact printhead can be integrated into production lines with a high degree of flexibility, making installation easier even where space is limited or packaging geometries vary. Having demonstrated the prototype at interpack, LEIBINGER is planning pilot trials and demo installations for the end of this year and commercial launch of 2DJET in early 2027
At interpack in May this year, LEIBINGER unveiled its 2DJET™, a new coding class and a completely new approach to industrial coding and marking. Built to solve a key challenge currently facing the packaging industry – the transition to GS1 2D codes – 2DJET delivers razor-sharp, GS1-compliant 2D codes at up to 300 dpi and printing speeds of up to 120 m/min across a wide range of packaging materials and formats, without compromising productivity or flexibility. It is designed for seamless integration into existing production lines and is easy to install and operate, helping manufacturers simplify implementation and GS1- compliant day-to-day production. 2D codes – setting the pace for the future In packaging, across food, beverage, pharmaceuticals, and FMCG, 2D codes are rapidly becoming the new standard. They promise more data in less space, improved traceability, greater flexibility in information management, stronger consumer engagement, and better control across the value chain – with relevance extending to emerging requirements such as the EU Digital Product Passport.
Real print samples: 2DJET™ delivers razor-sharp, GS1-compliant 2D codes at up to 300 dpi and printing speeds of up to 120 m/min across a wide range of packaging materials and formats.
For more information visit: www.leibinger-group.com
JUNE 2026 Electricity + Control
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Control systems + automation
Smart milling – efficiency, consistency and competitiveness Digitalisation, automation, and data-driven decision-making are transforming the global milling industry. The SmartMill approach is emerging as a pathway to improved eiciency, consistency, and competitiveness. Swiss technology company Bühler highlighted these developments at the 90th congress of the National Chamber of Milling (NCM) held earlier this year in Knysna, Western Cape. S peaking at the event, Fabio Curatolo, Senior Customer Relationship Manager at Bühler Southern Africa, outlined how the SmartMill concept is helping millers respond to growing operational pressures, tighter margins, and increasing quality and compliance demands.
through a process that spans consulting, engineering, digital solutions, and ongoing operational support. “Our goal is to help millers translate data into measurable improvements in yield, energy use, and plant performance,” says Curatolo. The technologies that help to enable this transformation include advanced automation systems, digital production management platforms, and specialised process optimisation tools. For example, Bühler’s digital platforms like Bühler Insights and ProPlant allow millers to organise and monitor maintenance, production, and process data in real time. Solutions such as temperature and vibration monitoring help optimise grinding performance and reduce energy consumption. One advantage of the SmartMill approach lies in it being an incremental journey rather than an abrupt change. This allows customers to join at the point that best suits their business, then the pace and direction of the journey is up to each company. Bühler says anyone thinking of being part of the journey going forward, should be thinking now about installing sensor technology and the connectivity that oers the necessary production transparency to inform decision making. This is the foundation for the whole SmartMill process. Increasing digitalisation Curatolo expects digitalisation in the milling sector to accelerate significantly over the next decade. “We expect to see wider use of automation, with AI-driven analytics for process optimisation, predictive maintenance, and to meet the increasing requirements for full traceability across the value chain,” he says. “Sustainability will also be a major driver, pushing mills to reduce energy use, emissions, and waste, as well as improving resource eiciency.” However, Curatolo emphasises that a successful SmartMill journey requires more than installing new technologies. “The SmartMill works best when it is implemented as a practical, step-by-step programme,” he says. “Clear performance targets, a reliable data foundation, and strong operator engagement are essential. When those elements come together, the result is more eicient, resilient, and competitive milling operations.” Innovation remains at the core of Bühler’s long-term competitiveness and its ability to create impact for customers. In 2025, R&D expenditure amounted to 4.8% of turnover and the Bühler Group launched 60 new products successfully into the market, reinforcing its commitment to purposeful innovation driving performance and sustainability. The group’s innovation capability is supported by Bühler’s global innovation network of 26 research and training centres.
Curatolo explains that SmartMill is not a product, but a concept, incorporating hundreds of complementary innovations designed through close collaboration with the industry. It represents a shi£ towards more connected, transparent, and automated milling operations. Integrating sensors, digital platforms, and advanced analytics, mills can move from manual checks and experience-based decisions to real-time data-driven process control. “The SmartMill means using connected
Fabio Curatolo, Bühler Southern Africa.
equipment, sensors and so£ware to make milling operations more predictable and responsive,” says Curatolo. “Operators can rely on real-time data to maintain optimal performance, ensure consistent quality, and react faster to deviations.” A complex operating environment Like other industrial operations, millers today face a complex operating environment. Variable raw material quality, rising energy and utility costs, maintenance reliability challenges, and skills shortages are making consistent production performance more diicult to maintain. At the same time, the market is demanding tighter margins, greater traceability, and higher standards of food safety and quality. “In South Africa, these pressures are more pronounced as a result of energy instability and rising operating costs,” notes Curatolo. “SmartMill technologies help millers address these challenges by improving process control, strengthening traceability, and making operations more resilient.” Digital monitoring and data collection play a central role in this transformation. “Data turns milling from a ‘best eort’ operation into a controlled, evidence-based process,” he says. “By analysing trends and detecting changes early, mills can adjust parameters proactively, prevent downtime, and maintain consistent output.” The SmartMill approach Bühler supports millers in transitioning to smart milling
For more information visit: www.buhlergroup.com
8 Electricity + Control JUNE 2026
Control systems + automation: Products + services
30 years of TwinCAT – a single platform for all automation functions
of the all-electric machine, more powerful, more precise, and more eicient solutions could be implemented early on. Even then, the visionary so£ware-centric approach liberated machine builders from the narrow performance limits of conventional control hardware in a way that would stand the test of time. Openness and functionality A key way in which the TwinCAT architecture adds value results from its openness, which consolidates the full spectrum of automation in a single so£ware concept. While the focus was initially on PLCs, motion control, and I/Os, the platform now comprises well over 100 highly specialised functions, including functions for high-performance measurement technology, control technology, and communication. All machine functions are thus calculated deterministically on a central industrial PC and transferred to the I/O level with exact clocking via the high-speed EtherCAT fieldbus. This allows processes to be controlled and regulated with top temporal resolution and accuracy. In terms of practicality, the installation work, space required in the control cabinet, and overall costs are all reduced. The performance capability of advanced industrial PCs also facilitates seamless integration of many other high-end technologies. Machine vision with TwinCAT Vision and the system-integrated robot controller are anchored in the so£ware as native runtime modules. Implementing artificial intelligence is rapidly increasing in importance. The TwinCAT Machine Learning Creator can be used to generate AI models for analysing image data, time series, and process data without any previous experience or prior knowledge, making local monitoring solutions and anomaly detection possible directly in the control environment. The TwinCAT CoAgent assistance tool supports users throughout the life cycle – from engineering to live machine operation. Fit for the future As the so£ware-centric design of the architecture continues to work on the inherent principle of scalability and convergence with IT, even three decades a£er its market launch, TwinCAT users are well equipped for future challenges. PC-based control provides an ideal foundation for deep IT/OT integration and integration into cloud or edge infrastructures. Whether physical AI, new communication standards, or stringent cybersecurity concepts – TwinCAT adapts all new market requirements as a modular framework. At the same time, machine builders are safeguarding their ability to innovate in the long term with the combination of computing power, availability, and openness the platform provides.
The introduction of TwinCAT in 1996 marked a decisive evolutionary step in the model for PC-based control. With the switch from DOS to Windows, programming in accordance with IEC 61131-3, and integrated engineering, Beckho created a solution based on the principle of separating hardware and so£ware. Today, the TwinCAT platform combines all automation functions in a strictly deterministic, real-time environment – from PLC and motion control through CNC and measurement technology and beyond to vision, robotics, and pioneering AI tools. By abstracting the control function from proprietary device hardware, Beckho achieved a paradigm shi£ in automation. Building on this, the market launch of The Windows Control and Automation Technology (TwinCAT for short) 30 years ago established the basis for the success PC-based control sees today. TwinCAT provided a means for transferring IT standards to automation and building them into an integrated, high- performance and deterministic control platform with real- time extensions – initially with a focus on Windows, but since then also on operating systems such as TwinCAT/BSD and Linux®. In addition, Beckho combined all the engineering in a single so£ware concept and supported globally established PLC programming conforming to IEC 61131-3, as well as IT standards including C, C++, MATLAB®, and Simulink®. From the start, TwinCAT has been characterised by outstanding performance data: PLC cycles were radically shortened to as little as 100 µs and main memory became available in almost unlimited quantities. TwinCAT also oered extremely powerful motion functions, from simple standard axes to electronic gearing and cam plates to 5-axis CNCs. The number of axes that could be controlled grew every year, from 10 to 50 to 100 to over 1 000 axes today, with the cost per axis sinking simultaneously. With the concept For 30 years, TwinCAT by Beckhoff has provided an integrated software foundation for PC-based control technology across all industries and automation functions.
For more information visit: www.beckhoff.co.za
JUNE 2026 Electricity + Control
9
Renewable energy + industrial sustainability
Diverse energy sources meet growing global demand
According to the latest edition of the International Energy Agency’s (IEA’s) Global Energy Review , worldwide energy demand grew at a slower pace in 2025 than in the previous year, but electricity consumption continued to rise much faster than overall demand – with solar PV becoming the largest contributor to growth in global energy supply for the first time.
against a complex economic and geopolitical backdrop, with one trend unmistakeable: the expanding electrification of economies. Electricity consumption is growing faster than overall energy demand – and solar PV is growing faster than any other energy source. It ac- counted for over a quarter of the world’s energy demand growth – more than any other source, for the first time. Natural gas followed. In today’s rapidly shi£ing landscape, countries that prioritise resilience and diversification will be best placed to manage volatility and deliver secure and aordable energy in the years ahead.” Beneath the global totals, trends diverged sharply across major economies. Energy demand growth in the United States rose to its second-highest level this century – excluding post-recession recov- ery years – boosted by strong electricity demand from data centres, robust industrial activity and colder winter temperatures. China ac- counted for the largest overall share of global energy demand growth last year, but its growth rate dropped sharply to 1.7% as renewables displaced coal, which is less eicient, and broader energy eiciency gains strengthened. At the same time, growth in global energy-related CO 2 emissions slowed in 2025, rising by around 0.4%. According to the report, Chi- na’s emissions declined in 2025, supported by a surge in renewables and other low-emissions technologies. India’s energy-related CO 2 emissions were flat for the first time since the 1970s – excluding the Covid-19 pandemic – with the eects of an unusually strong monsoon season playing a significant role in curbing emissions growth. By con- trast, in advanced economies, an especially cold winter pushed fossil fuel use and emissions higher. Taken together, these developments meant that emissions from advanced economies grew faster (+0.5%) than those from emerging and developing economies (+0.3%) for the first time since the 1990s. In the electricity sector, the additional 600 terawatt-hours of so- lar PV generation worldwide in 2025 marked the largest structural increase ever recorded in a single year for any electricity generation technology, contributing to a decline in coal-fired electricity genera- tion globally. Battery storage was the fastest-growing power sector technology in 2025. The roughly 110 gigawatts of new battery storage capacity added during the year exceeded the largest annual capacity additions to date for natural gas. In nuclear power, construction be- gan on over 12 gigawatts of new nuclear reactors in 2025, a reflection of renewed momentum for nuclear projects in several regions. The IEA reports that cumulative deployment of low-emissions technologies since 2019 now means the avoidance of annual fossil fuel consumption equivalent to the entire energy demand of Latin America. Use of technologies such as solar PV, wind power and heat pumps now displaces natural gas demand equivalent to half of all global annual LNG exports. The report and an accompanying dataset can be downloaded from the IEA website.
T he report provides a comprehensive global assessment of trends across the energy sector in 2025. Based on the latest data, it covers energy demand, electricity generation and use, energy technology deployment and energy-related car- bon dioxide emissions. Global energy demand growth slowed to 1.3% in 2025, slight- ly below the previous decade’s average of 1.4% and significant- ly lower than in 2024 amid lower global economic growth, less extreme temperatures in some regions and the rapid uptake of more eicient technologies. At the same time, global electricity demand increased by around 3% – slower than in 2024, but still above the average of the past decade. Electricity demand growth was driven by multiple sectors across buildings and industry – and boosted by fast-growing de- mand from electric vehicles and data centres. In terms of energy generation, all major fuels and technolo- gies expanded in 2025 to meet rising demand, although at very dierent rates. Solar PV was the single largest contributor to growth in global energy supply, accounting for more than 25% of the increase – the first time on record that a modern renewable source has led growth in global primary energy supply. Natural gas took the next largest share, at 17%, reflecting its critical role in power generation in many countries. Overall, renewable sources and nuclear met nearly 60% of all growth in energy demand – and power generation from these sources exceeded total growth in electricity demand. Global oil demand rose by 0.7%, in line with IEA projections. This reflects continued growth of electric vehicles, which con- strained demand for road fuels. Electric car sales in 2025 in- creased by over 20% to more than 20 million units – making up around one in four new car sales worldwide. Strong renewables growth reduced coal use in power generation in China, although coal demand increased in the United States as high natural gas prices drove gas-to-coal switching in electricity generation. Over- all, the rate of coal demand growth slowed in 2025. Commenting on the report, IEA Executive Director Fatih Birol said: “Global energy demand continued to increase in 2025
The world’s energy demand increased more slowly last year against a complex economic and geopolitical backdrop, but electricity use continued to rise strongly.
For more information visit: www.iea.org
10 Electricity + Control JUNE 2026
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