Optimizing processes while also conserving resources
The PLCnext Factory in Bad Pyrmont demonstrates that analyzing minimal process data with Phoenix Contact’s advanced technologies can yield significant savings.
Bad Pyrmont, a scenic town in Germany’s Weserbergland region, is home to Phoenix Contact’s PLCnext Factory—a cutting-edge automation facility. It tests and implements new technologies like the Industry 4.0-based Digital Factory and net-zero carbon concepts. The factory also produces the very technologies that will power future production systems.
Progressive digitalization is key to automation technology, requiring the acquisition, collection, and evaluation of production data. Only with data transparency can processes be optimized, resources conserved, and overall equipment effectiveness improved.
Minimally invasive acquisition of energy and process data
Data acquisition is essential for future viability of a businesses, both in existing and new facilities. Phoenix Contact’s Digital Factory now solution tackles digitalization step by step—from intelligent energy data collection and secure automation to AI analysis, cloud connection, and Smart Services. In the PLCnext Factory, minimally invasive Data Collection Boxes collect extensive energy and process data without affecting onging operations or affecting CE compliance, avoiding recertification. Just 3–5% of sensor and actuator data is enough to map processes comprehensively, with AI enriching and analyzing the data.
You can integrate the Data Collection Box into existing production facilities, choosing from standard or fully customized hardware and software versions. In most cases, parameterization replaces programming, reducing setup effort. Built for OT data collection, its modular design simplifies expansion. The IIoT framework enables seamless data exchange beyond OT, integrating easily with common IT and cloud systems for unrestricted communication.
Simple solution for creating machine learning models
A large amount of data is generated in the Digital Factory which needs to be analyzed. Machine learning offers clear advantages over manual evaluation. Phoenix Contact’s MLnext simplifies the creation and deployment of ML models, scalable from individual machines to entire production lines. This enables automated optimization, reducing downtime and boosting productivity—by 10% in the PLCnext Factory.
Comprehensive access protection with 360-degree security
Secure data acquisition is critical, especially amid rising cyber threats and evolving regulations. Machine builders must now comply with the new EU Machinery Regulation and Cyber Resilience Act. While operators of large facilities face the NIS 2 directive. Although implementation standards are still being harmonized, the globally recognized IEC 62443 is expected to serve as the foundation for these efforts.
Phoenix Contact follows IEC 62443, applying a 360-degree cybersecurity approach across product security, network design, and employee training. TÜV-certified elements include secure development (IEC 62443-4-1), compliant devices like PLCnext Control and FL mGuard (IEC 62443-4-2), a remote maintenance blueprint (IEC 62443-3-3), and secure automation design (IEC 62443-2-4).
Secure network design requires careful planning—identifying assets, assessing risks, and protecting critical components. In the PLCnext Factory, Phoenix Contact’s Data Security Box ensures secure, user-friendly data communication through network segmentation. The company also provides employee awareness training and certified experts to design secure network architectures.
Further reduction of energy consumption based on sector coupling
Complete transparency of energy data enables more reliable and verifiable progress toward sustainability goals. Knowing where resources are used in the value chain allows targeted actions to reduce consumption and optimize processes. This makes energy data collection and analysis essential for climate-neutral production.
The PLCnext Factory features 66,500 measuring points that collect and analyze data in real time, enabling immediate detection of irregularities and supporting efficient, sustainable processes. Phoenix Contact also applies sector coupling—linking energy, industry, infrastructure, and mobility—to optimize energy use and advance toward a net-zero factory.
The PLCnext Technology open ecosystem as a fundamental basis
At its Bad Pyrmont site, Phoenix Contact runs a model Digital Factory that produces innovative automation components using fully digitalized, net-zero-oriented processes. The open PLCnext and MLnext ecosystems integrate all machines seamlessly, enabling comprehensive data collection and analysis to boost efficiency and support sustainability goals.
Learn more about Digital Factory.
