PII Podcast

A regular series where our expert host Dave Howell discuses the latest technologies and future insights throughout the manufacturing process industries

Energy Savings as a Growth Engine: How SMEs Can Turn Renewable Power into Productivity 04/10/2026

Driving Change: How Hyper-Efficient Motors Are Reshaping Industries 03/27/2026

Driving Change: How Hyper-Efficient Motors Are Reshaping Industries Hosted by David Howell, this episode explores how hyper-efficient motor technologies are transforming industrial performance, sustainability and long-term competitiveness. As a global leader in motors and drives, ABB Motion sits at the forefront of accelerating a more productive and sustainable future. Through continuous innovation, it is helping industries transition towards energy-efficient, decarbonised and circular operations. Electrification, digitalisation and circularity are now converging to fundamentally redefine how industrial systems operate. High-efficiency motors and digital powertrains are enabling organisations to optimise performance while significantly reducing emissions. From heavy industry and manufacturing to transport and buildings, these technologies are supporting everything from renewable integration to electric mobility. This is not a gradual shift. It is a systemic transformation in how energy is produced, managed and consumed. In this episode, David Howell is joined by Daniel Eberli, Global Business Line Manager at ABB, to unpack the forces driving this change and what it means for industrial leaders. Episode Overview Industrial motors continue to account for a substantial share of global electricity consumption, yet they have historically been overlooked as a major efficiency opportunity. Often regarded as the “silent workhorses” of industrial plants, many systems remain unchanged for years, driven by a “if it isn’t broken, don’t fix it” mindset—despite hidden inefficiencies steadily draining energy and cost. With nearly half of installed motors now more than a decade old, the scale of the opportunity is significant. In recent years, however, energy efficiency has moved from a technical consideration to a strategic priority. Governments worldwide have recognised its critical role in energy security and industrial competitiveness, resulting in tighter regulations and minimum efficiency performance standards. At the same time, volatile energy prices have sharpened focus on operating costs, with electricity accounting for the overwhelming majority of a motor’s total cost of ownership. As a result, businesses are increasingly prioritising efficiency not only for sustainability but also for clear financial returns. Successful organisations are taking a structured, systems-level approach to efficiency. Rather than relying on ad-hoc upgrades, they are conducting comprehensive energy appraisals, identifying high-impact opportunities and implementing clear roadmaps. Case studies such as Aurubis demonstrate the potential: large-scale upgrades to high-efficiency motor systems can deliver substantial energy savings, reduced emissions and rapid payback periods, while also simplifying operational complexity. A key insight discussed in the episode is the true cost profile of industrial motors. While initial purchase costs are minimal, energy consumption dominates over the lifecycle. This makes efficiency improvements one of the most effective levers for reducing both operational expenditure and environmental impact. Advances in motor technology, including ABB’s latest synchronous reluctance solutions, are now delivering measurable gains in performance, reliability and lifecycle cost. Digitalisation is further accelerating this transformation. The integration of AI, predictive analytics and variable speed drives is enabling real-time optimisation of energy use and early detection of potential failures. By aligning energy consumption with actual demand and improving system reliability, organisations can unlock additional efficiency gains while reducing downtime. Real-world implementations, such as GSK’s Singapore facility, highlight how digital monitoring and predictive capabilities can exceed performance targets and deliver strong returns on investment. Electrification and energy efficiency are increasingly working hand in hand. High-efficiency motor technologies deliver the greatest impact in continuous-duty applications such as pumps, fans and compressors, which represent a large proportion of industrial energy use. However, scaling these solutions requires careful consideration of application-specific requirements and long equipment lifecycles, reinforcing the importance of selecting the right technology from the outset. Circularity is also becoming a practical reality within industrial operations. Modern motor designs are highly recyclable, and innovations in materials—such as the use of low-carbon and recycled copper—are reducing embedded emissions. Combined with transparent lifecycle assessments, these developments are enabling organisations to align operational improvements with broader ESG objectives. Key Takeaways for Business Leaders For organisations looking to accelerate their energy transition, the episode highlights three critical actions: Conduct a comprehensive fleet-wide energy audit to identify inefficiencies and prioritise high-impact opportunities Develop a structured upgrade roadmap, focusing on replacing outdated motors with high-efficiency alternatives and integrated drive systems Implement real-time energy monitoring to track performance, validate savings and continuously optimise operations Final Thoughts Many organisations are still at an early stage in their efficiency journey, working to quantify energy use, identify savings opportunities and prioritise modernisation investments. The path forward requires a clear, structured progression—from insight to implementation and ongoing optimisation. For today’s industrial leaders, the challenge is balancing immediate operational demands with long-term sustainability goals, while unlocking both financial and environmental returns. To learn more and begin your journey, visit ABB. /episode/index/show/piipodcast/id/40642245

50 Years of Precision with Beamex 01/09/2026

Measured Truth: Why Calibration Powers Industrial Innovation 12/08/2025

Every Drop Counts: The Critical Role of Calibration in Water Quality 10/01/2025

Inside ABB’s ACS380-E: The Future of Smart Machinery Drives 09/26/2025

Smarter Machines, Stronger Businesses: AI’s Role in the Next Era of Manufacturing 09/15/2025

Smarter Machines, Stronger Businesses: AI’s Role in the Next Era of Manufacturing In this podcast with Keith Smith, Chief Operating Officer and Co-Founder of IntelliAM, we are considering the role of AI in manufacturing – exploring the current challenges facing the industry as well as myth-busting the common barriers to adoption. IntelliAM – which stands for intelligent asset management – is a UK tech company specialising in AI and machine learning for the manufacturing industry. Many of the world’s largest manufacturers – including half of the world’s top 12 FMCGs – are using IntelliAM’s solution to unlock insights from billions of machine asset data points. IntelliAM is on a mission to revolutionise the machine asset management industry – using AI to increase productivity, cut operating costs and drive smarter decision-making on the factory floor. About Keith Smith: Keith is the Chief Operating Officer and Co-Founder of IntelliAM. He has 27 years of experience in the manufacturing and engineering industry, including extensive expertise in the FMCG sector. He specialises in the development and promotion of Asset Care Standards that help manufacturers unlock the full potential of their operations. In his role at IntelliAM, Keith leads all operational teams, driving the development of the IntelliAM platform to help customers achieve world-class asset care standards. He’s able to speak about AI adoption within the manufacturing sector and how it can help manufacturers to unlock greater productivity, quality, performance, efficiency, and safety, while also reducing waste and increasing throughput in the UK’s manufacturing sector. Topics include: What the biggest pressures facing manufacturers today and how rising demands and shrinking resources are reshaping the way they operate. Why traditional predictive maintenance systems are struggling to keep up with modern manufacturing environments Examples of how outdated maintenance methods are leading to costly downtime or inefficiencies on the plant floor Ways AI fundamentally changes the maintenance game, particularly in interpreting asset data and predicting failures before they happen Limitations of traditional condition monitoring tools and human interpretation and how does IntelliAM's approach go beyond them? IntelliAM’s six-step AI model: a structured journey rather than a quick fix The importance of industry-specific knowledge in AI deployment and how IntelliAM bridges engineering expertise with technology Common misconceptions about AI adoption in manufacturing, from job loss fears to ROI concerns Shifting mindsets from reactive to proactive maintenance and how AI helps manufacturers lead rather than follow The future of intelligent maintenance and how manufacturers can prepare today /episode/index/show/piipodcast/id/38225275

Goodbye Downtime: How Real-Time Spectroscopy Boosts Safety & Efficiency 08/01/2025

Beyond Pneumatics: Why Electric Pumps Are Reshaping Industry 07/16/2025

Precision in Progress: Digital Calibration for Modern Manufacturing Processes 12/16/2024

AI-Driven Transformation: How Innovation is Shaping the Future of Manufacturing 09/11/2024

Creating a More Competitive and Skilled Manufacturing Workforce 08/07/2024

Creating a More Competitive and Skilled Manufacturing Workforce In this episode, Shawn Dagley, Kahuna’s Director of Manufacturing, discusses how Kahuna’s data-driven approach to skills management enables leaders to understand their skills supply and demand to make informed staffing decisions in dynamic environments. Kahuna digitises, manages, and validates workforce skill, competencies, experiences, certifications in one to increase efficiencies, standardise training and development programs, close skills gaps, mitigate operational risks, increase safety, and guide strategic operating decisions with validated skills insights. From a manufacturing perspective, Shawn and the Kahuna team see four main drivers for establishing a skills-based approach and practice: Worker attainment – There is a severe shortage of manufacturing expertise available in the market today. A well-organised skills management program can help search for the right type of candidate and develop the candidate’s proficiency in the required skills. This method broadens the scope of the job search and improves retention chances within the organisation by supporting development efforts. Worker retainment – Employee satisfaction leads to lower attrition rates. Data shows the average tenure of a manufacturing employee has fallen from 20 years in 2019 to only three years in 2023. With an easily accessible and standardised skills management program, employees have visibility into skills and training requirements, empowering them to own their learning journey within the organisation and shows them the business is invested in their development. Capitalising on the investment in Industry 4.0/Smart Factory – Many companies are investing significantly in I4.0 technologies. Things like Connected Equipment, Additive Manufacturing, Virtual and Augmented reality, Predictive Maintenance. But companies are forgetting to invest in their workforce to maximise the investment in this equipment. Increased product complexity – As products get more complex with the introduction of electronics, software, and AI built in, companies need to expand the capabilities needed in the design and manufacturing of these products. This will drive new skills requirements for teams and individuals. Don’t miss this episode and the opportunity to improve skills management and operational excellence initiatives within your manufacturing environment. Get in touch with Shawn Topics include: The key benefits of shifting to skills-based practices in manufacturing How skills management contributes to the efficiency and flexibility of the workforce Why companies struggle with using Excel for skills management How the Kahuna Skills Management Platform works and its core features Real-time visibility into workforce capabilities, and why is this important How skills management supports initiatives like Smart Factories and improves overall equipment efficiency Compliance with quality, safety, and environmental standards How tying compensation to upskilling can increase workforce flexibility Success story of a client who significantly benefited from implementing Kahuna’s skills management system Integrating with other systems like Core HRIS, Learning Management Systems, and Planning & Analytics tools What the first steps are transitioning to a skills-based management system /episode/index/show/piipodcast/id/32472207

NSI Mobile Water Solutions 06/26/2024

Pioneering the future of Process Analysis 04/03/2024

Radial Insert Ball Bearings technology 03/28/2024

Radial Insert Ball Bearings technology For machines in the food industry, you need special solutions. Extreme temperatures, high mechanical loads, short cycle times, round-the-clock operation, and regular cleaning cycles require very robust components. Strict food safety regulations pose as much of a challenge here as efficiency and sustainability. Whether it’s for process automation in food production, for beverage production or the packaging industry, in all cases you need food-compatible rolling bearings, plain bearings, and linear guidance systems as well as adapted lubrication and seal concepts. Even during the planning stage of your machines, it is already important to find the right rolling bearing solution for your application, for example with the aid of simulation tools. And with permanent condition monitoring, you create the best conditions for the reliable, hygienic, and economical operation of your equipment. Learn more about how you can successfully meet the challenges of the food, beverage, and packaging industry. In this podcast we are considering Radial Insert Ball Bearings technology and also Scheffler's condition monitoring technology, Optime. My guests today are Tom Richmond, Scheffler’s Food and Beverage Sales Engineer and Sally Sillis, Shefler Technical Manager. Topics include: What makes Radial Insert Ball Bearings technology particularly applicable to the Food & Beverage industry. Overview of Scheffler's condition monitoring technology, Optime and its core principles. How Schaeffler’s Condition Monitoring services and technologies support customers. How important is FDA certification. How Schaeffler is involved with the design stage of a new process, or helping customers to evolve existing systems and processes. An outline the sustainability credentials of Optime and Radial Insert Ball Bearings technologies. Why contact bearings or combined radial and axial loads are particularly applicable to the food and beverage industry. How Optime can be integrated into existing machinery and control systems. /episode/index/show/piipodcast/id/30577428