Powering Smart Manufacturing at Scale
Industrial automation is entering a decisive phase. What began as digitalization and connectivity under Industry 4.0 is evolving into intelligent, adaptive and energy-aware production ecosystems aligned with Industry 5.0. Artificial intelligence, advanced robotics and autonomous control systems are no longer experimental technologies and are now embedded across factory floors, logistics systems and energy infrastructure.
As automation platforms grow more computationally intensive and operate continuously, power electronics and industrial control systems must perform with optimum efficiency. Reliability is no longer a supporting feature; it is a competitive differentiator.
Rising demand reshapes power conversion architecture:
Global energy consumption is rising, driven by electrification, automation and data intensive workloads. The International Energy Agency (2026) projects that electricity demand over the next five years will increase at a rate around 50% higher than the past decade, as manufacturers scale AI-enabled automation and intelligent industrial systems.
The industrial automation and control systems market is also forecasted to grow at double-digit rates through the decade, reflecting strong investment in robotics, motion control, sensors and digital power management. This growth places new expectations on power generation, conversion and distribution systems to deliver uninterrupted performance under increasingly complex conditions.
Five shifts redefining power and industrial automation:
- High-density power conversion: Modern AC/DC and DC/DC converters are being redesigned to deliver higher power in smaller footprints. Greater efficiency, wider input ranges and digital monitoring capabilities help reduce energy losses and improve uptime.
- Microgrids and grid decentralization: Manufacturers are moving closer to localized energy generation. Microgrids, on-site storage and intelligent energy management systems improve resilience, stabilize sensitive automation equipment and reduce dependence on centralized grids.
- Data-driven infrastructure: Industrial data centers and edge computing nodes now sit alongside production lines. These facilities demand highly reliable power architectures, modular designs and optimized thermal management to support real-time analytics and AI workloads.
- EV and electrified mobility systems: Automated guided vehicles (AGVs), autonomous mobile robots (AMRs) and EV charging infrastructure are increasing electrical loads within industrial sites. Power systems must withstand dust, vibration, moisture and thermal stress while operating safely and continuously.
- Renewable integration: Solar, wind and energy storage solutions are increasingly embedded within industrial operations, lowering emissions while supporting high-availability automation. While these resources offer environmental benefits, they also require sophisticated control systems capable of balancing supply, demand and reliability.
Advanced materials enable reliable automation:
As controllers, drives and processors deliver more capability in smaller packages, thermal stress is becoming a key engineering challenge. Higher operating temperatures, continuous duty cycles and harsh environments can accelerate component degradation and increase the risk of failure. Effective heat dissipation and protection are therefore essential for long term reliability.
Advanced materials help industrial power systems operate safely and efficiently:
- Thermal management materials dissipate heat from compact power electronics, supporting higher power density and reliability.
- Protective coatings, gaskets and encapsulants help shield sensitive components from moisture, dust and chemical exposure.
- Structural and thermally conductive adhesives enhance vibration resistance, simplify assembly and support more compact device designs.
Looking ahead:
As industrial systems become more sophisticated, the demands placed on power electronics, automation platforms and energy infrastructure will continue to rise. Meeting these challenges will require innovation across the entire ecosystem, from smarter power architectures and resilient energy networks to the advanced materials that enhance thermal performance, environmental protection and long-term reliability.
At Henkel, we help manufacturers transform ambitious concepts into real world performance by powering and protecting the technologies shaping modern industry. Explore the invisible backbone of power conversion and industrial automation by downloading our new eBook. We help to put your #IdeasInMotion.
