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What is SCADA? A Simple Guide to Supervisory Control and Data Acquisition
Ever wondered how water treatment plants keep their operations running 24/7? Or how one operator can monitor hundreds of pumps
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The Evolution of Industrial Automation: 5 Big Shifts in 10 Years
The world of industrial automation has transformed rapidly over the past decade.
From manual systems to fully connected smart factories, the evolution of industrial automation has reshaped how manufacturers operate. It has boosted efficiency, reduced errors, and enabled remote control like never before.
In this article, we explore five major shifts that have defined the last 10 years of industrial automation, and what they mean for businesses today.
1. The Rise of Smart Factories and IIoT
This change is largely driven by the Industrial Internet of Things (IIoT), which links devices, sensors, PLCs, and cloud platforms into a single, data-driven network.
Key benefits of IIoT:
- Real-time monitoring of machine performance
- Predictive maintenance based on usage data
- Reduced downtime through early fault detection
For example, a smart factory can now use sensors to detect when a motor is about to fail, and alert the maintenance team before it breaks.
What this means for your plant:
If your system still runs on legacy automation without real-time connectivity, you may be missing out on serious efficiency gains.
2. Migration to Cloud-Based Control and Data Storage
Ten years ago, most industrial data was stored on-site or inside individual control systems. Now, that data lives in the cloud.
This shift to cloud-based industrial automation has opened up powerful new capabilities:
- Remote access to PLCs, HMIs, and SCADA systems
- Centralised data analytics and dashboards
- Easier collaboration between teams, regardless of location
Security concerns once held many businesses back, but today’s encrypted and secure cloud systems have addressed these risks.
Cloud-based automation is now the standard, not the exception.
3. The Shift From Hardwired to Software-Defined Control
Traditionally, industrial systems relied heavily on physical wiring and fixed-function hardware. Today, much of that functionality has moved to software.
This evolution of industrial automation means that:
- PLC programs can be edited, simulated, and deployed remotely
- One controller can now handle multiple processes
- Changes to logic don’t always require rewiring or hardware upgrades
Open-source programming environments and cross-platform tools (like Codesys) have made it easier for engineers to design flexible control systems that can grow with business needs.
Why it matters:
Software-defined automation lets companies adapt quickly to new product lines or market demands without huge infrastructure costs.
4. The Integration of AI and Machine Learning
The last few years have seen a surge in AI tools across many sectors and automation is no exception.
Artificial intelligence is now being used to:
- Optimise production processes
- Predict equipment failure with high accuracy
- Spot inefficiencies that humans may overlook
While AI is still emerging in many plants, early adopters are already seeing measurable gains in performance and productivity.
Machine learning is driving smarter automation. It’s not just faster or more precise, but also more adaptive. For example, AI can learn the optimal settings for a packaging line based on output targets, temperature, and material flow.
5. Sustainability and Circular Automation
As industries face increasing pressure to lower their carbon footprint, sustainability is no longer a side issue but a core part of industrial strategy.
This shift has driven:
- The use of energy-efficient drives, motors, and PLCs
- Systems that reduce waste and optimise raw material use
- A growing market for refurbished and repurposed automation parts
Mizen Automation, for instance, helps businesses source high-quality, refurbished components to extend the life of older systems. This approach keeps parts out of landfills and lowers replacement costs.
Sustainability in automation isn’t just about energy. It’s about smarter use of resources, reducing e-waste, and designing systems with longevity in mind.
What This Means for NZ Manufacturers
In New Zealand, many manufacturers are catching up with these global shifts. While some still run legacy systems, others are already moving toward smart, connected, cloud-driven factories.
Upgrading doesn’t mean starting from scratch.
Many modern PLCs and HMIs are backward-compatible or can be integrated with existing setups.
At Mizen Automation, we help clients make the transition—step by step—by:
- Supplying hard-to-find, obsolete parts
- Offering refurbished modules to reduce costs
- Helping businesses stay operational while upgrading gradually
Contact our sales team today to talk about how we can support your plant’s next step forward.
Final Thoughts
The evolution of industrial automation in the past decade has been fast and transformative.
To recap, the 5 biggest shifts include:
- The rise of smart factories and IIoT
- Cloud-based control and storage
- Software-defined logic over hardwiring
- AI-driven optimisation
- Sustainable automation practices
Adapting to these trends is not just about staying modern. It’s about staying competitive.
For a deeper look at global automation trends, check out the International Society of Automation’s industry news hub.
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