Smart factory critical infrastructure has become more intelligent in many ways. Experts are installing peripherals, such as sensors, to detect the smallest errors in real time. A leak or crack is less destructive to machinery, utility systems and even brownfield modernization efforts if technicians can take proactive measures. However, detecting vibrations or interference matters only if the structure is inherently sturdy and dependable. This is why manufacturers are moving away from brittle synthetics and retrofitting industrial equipment with heavy-duty iron.
Superior Total Cost of Ownership (TCO) and Long-Term Return on Investment (ROI)
While synthetic materials are potentially cheaper and viewed as a fixture of modern facilities, iron is the longer-lasting option. From a financial and life cycle perspective, organizations are retrofitting industrial equipment with the material, making it resemble legacy equipment. However, it has the modern edge of smart tools to maintain high performance and operational efficiency. The ROI is high, and the TCO is low.
A case study in an Italian milling plant proves this. It acquired stainless steel rollermills and determined its life cycle costs over periods of 15, 30, and 45 years. The steel equipment’s operational costs increased significantly over time. The reality negates the justifiable up-front expenses because maintenance is so expensive. Running costs were estimated at €847,994.04 over 15 years of activity and €2,380,559.08 over 45 years. This highlights the importance of heavy-duty equipment, such as iron.
Increased Reliability and Reduced Unplanned Downtime
Options like gray iron have become a staple of legacy industrial equipment because of their durability against common pain points, like corrosion and cracking. Employing smart sensors alongside it would make it even easier to preserve its longevity and improve production uptimes.
While it is dependable, preventing downtime also requires machinery that is effortless to repair. Iron is the fourth most abundant element on Earth. Because it is easier to procure than some contemporary materials used in equipment, it reduces long-term downtime. The metal's strength and abundance make replacement parts and additional retrofits less time-consuming to implement. In an era of supply chain volatility and disruption, choosing an accessible material for business-critical machinery is crucial for business continuity.
The Economic Viability of Brownfield Modernization
Taking a greenfield approach to a smart factory is exorbitantly expensive, whereas retrofits can be implemented gradually. This is a friendlier approach from a budgetary standpoint, as operators increase the value of legacy equipment by upgrading it with higher-quality iron components.
For example, polyvinyl chloride pipe fittings are lightweight but flexible and may eventually warp. Iron fittings are better able to withstand intense pressure while redirecting resources without losing integrity. Over time, organizations will spend less on regular replacements by having invested in parts that future-proof facilities as they adopt smart tech.
Enhanced Safety and Reduced Workplace Incidents
If equipment is more enduring and less prone to failure, then it automatically creates a safer working environment. Facilities seeking digitalization must avoid unnecessary expenses, such as workers' compensation claims and other safety costs. These delay implementation and efforts to upskill employees to the new smart assets.
Many equipment failures could lead to injuries that ruin worker morale or jeopardize output. If employees feel they are in danger due to unstable, modern equipment, it could lead to lower buy-in among the workforce toward a smart factory buildout. If the machinery's foundation is not durable enough to meet current industry demands, it will not matter how many sensors are present to predict failures. To ensure digitalization efforts unfold successfully, workers must feel confident and safe in their workflows, using these tools in ways that improve overall safety.
Enhanced Physical Cybersecurity and Reduced Attack Surface
The adoption of smart tech is increasing the attack surface in facilities. While many stakeholders are concerned about networks and servers, physical cybersecurity attacks remain a concern. The best barrier against these threats is durable, heavyweight materials that are difficult to compromise. Industry reports suggest physical consequences are becoming more common side effects of cyberattacks on operational technology, with a 146% increase in attack reach.
Consider an energy company undergoing a brownfield modernization project. It incorporates innovations like programmable logic controllers and network segmentation to protect its virtual spaces. However, the hardy, iron-based physical infrastructure remains rather than being replaced with cheaper alternatives for the sake of modernity. This allows the company to harness competitive advantages, especially during the energy transition, where iron is a critical component of energy storage. The heft provides stability, allowing this critical infrastructure and green energy to remain unmarred by cyber threats.
Achieving Operational Superiority Through Retrofitting Industrial Equipment
While there is a place for materials like thermoplastics, synthetic rubbers and carbon fiber, they fail to provide some of the benefits of conventional iron-made equipment. Industrial settings are adopting this resource again to withstand the harshness and pressures of modern production. With its compatibility with smart technologies, retrofits can deliver the benefits of high-tech operations while maintaining the robustness and security of heavy-duty iron.
