The Circular Economy

Hands free tool changes for smarter machining

Peter Pettersson, Sandvik Coromant Imagine a factory where the lights are off, not because no one is home, but because automated systems are working around the clock to keep production lines running with minimal human intervention. These futuristic setups are quickly becoming a reality, with touchless tool changes at the core of the automated machine cell. Unmanned machining represents a significant leap in manufacturing, where machines operate independently without the need for human supervision. Driven by CNC technology, robotics and automation software, these systems can run continuously — in some cases, 24/7 — performing tasks such as turning, cutting, milling and drilling with high accuracy. This approach enhances productivity, reduces errors and allows for efficient, around-the-clock operation. While many view unmanned machining as a futuristic approach to manufacturing production, Sandvik Coromant began reaping its benefits back in the 1980s. Going hands free Some 40 years ago, Sandvik Coromant’s production site in Gimo, Sweden, used a form of automatic tool change (ATC) that facilitated the changeover of machine tools without human input. The solution was offered as a product to customers, but it didn’t prove popular. Many could not grasp how ATC could save their machine shop time and enhance their productivity and the offering was dissolved. Fast forward a few decades and Sandvik Coromant continued to see value where others could not. This time around, the company worked with a machine builder to develop a second ATC solution. Again, it was implemented at the Gimo production facility and continues to run across several machine cells today. Using conventional tool management methods, a lathe could run without human input for around four-to-eight hours. After that, the tool would reach the end of its life and a human worker would need to stop what they’re doing to manually switch the tool with […]

Using AI to enable scalable, autonomous operations

By Troy Mahr, director – Kalypso. Kalypso – acquired by Rockwell Automation in 2020 – is a diverse team of consultants, innovators, strategists, data scientists and technologists. What we consistently hear from industry leaders is the need for real-time visibility across their global operations, which is key to ensuring their operations stay agile and scalable. However, achieving this isn’t possible without removing laggy manual data collection through the deployment of connected assets and contextualised data. By eliminating data silos and unlocking industrial data and artificial intelligence (AI) capabilities, companies can enable autonomous decision-making that optimises costs, efficiency, and production resilience. This moves their organisation closer to achieving autonomous operations. Autonomous operations are the manifestation of “self-governing” systems at every step of the manufacturing process. These systems derive their autonomy from data-led decision-making models that enable them to reliably adapt their behaviour in response to dynamic environments during operation without any manual intervention. Achieving autonomy across an enterprise requires capabilities that span the full intelligence spectrum, from observation and inference to decision-making and action. These capabilities are relevant across all operational areas, including product design, manufacturing, supply chain, distribution, direct-to-customer channels, and demand forecasting. Manufacturing operations, in particular, have seen progress through Model Predictive Control (MPC), which continuously analyses real-time and forecasted data to optimise process control within defined constraints. While MPC is a strong example within manufacturing, broader autonomy demands extending similar intelligent systems across the enterprise. This journey is captured in the industrial AI maturity pyramid, which outlines a progression from basic data integration and visualisation to predictive analytics, prescriptive decision-making, and ultimately, autonomous operations. As organisations climb this pyramid, they adopt machine learning, real-time automation, and self-learning systems. Each stage requires not just technological upgrades but also cultural and structural transformation. Asset Monitoring: Find Downtime Root Causes Looking at […]

A global treaty to limit plastic pollution is within reach

Winnie Courtene-Jones, Lecturer in Marine Pollution, Bangor University. Representatives from 175 countries will gather in Geneva, Switzerland, in August for the final round of negotiations on a legally binding UN treaty to end plastic pollution. Non-governmental organisations, academics and industry lobbyists will also be in the room. They will all be hoping to influence what could be the world’s first truly global agreement on plastics. The summit, known as “INC-5.2”, follows a failed attempt to reach agreement in Busan, South Korea, late last year. That meeting ended without resolving important issues, despite hopes that it would conclude the treaty process. Now, it’s crunch time in Geneva. Either countries bridge their political divides, or risk the whole process falling apart. I’ve been researching the effects of plastic for more than a decade and have been involved in the UN treaty process since 2022. I’ve attended several of the negotiations and will be in Geneva next month. The science is clear: we need ambitious action which tackles every stage of the plastics lifecycle, from production through to disposal. But the question is, will countries deliver? In 2022, the UN Environment Assembly agreed to develop a legally binding treaty to end plastic pollution. Since then, progress has been slow. Negotiations have repeatedly stalled over issues such as whether the treaty should limit plastic production or regulate chemicals, how to define terms, and how to fund implementation. Environment activists calling for a strong global plastics treaty in Busan, South Korea, December 2025. Associated Press/Alamy Industry lobbying has also played a powerful role throughout. At the last round of talks, lobbyists for the petrochemical and plastics industries made up the single largest delegation. They outnumbered representatives from the EU, all of Latin America, the Pacific islands, independent scientists and Indigenous communities. This imbalance threatens to weaken the science-based action that is urgently […]

Powering remanufacturing with AI

Companies are accelerating remanufacturing as a way to mitigate supply chain shortages, reach new customers through affordability, and implement high-margin alternatives for parts. However, those looking to build or optimise their remanufacturing operations face unique challenges, such as pricing a long tail of SKUs and undertaking accurate core forecasting—that is, predicting the volume, timing, and quality of returned products (core) that will be available for remanufacturing. Enter AI. As the costs of cloud storage and processing and prepackaged tools decrease, AI is becoming more accessible for organizations, helping them improve efficiency, yield, and margins. Unlocking AI in remanufacturing AI is an umbrella term for leading-edge techniques and methods of analysing data, predicting outcomes, and generating insights. While AI and gen AI technologies have garnered a lot of attention, they are only part of the AI landscape. Core forecasting The unpredictable nature of core availability is a challenge for remanufacturers, and conventional analytics lack the sophistication needed for predictive analysis. Introducing a specialised system such as a forecasting tool could help remanufacturers evaluate core availability at a per-SKU level. This forecasting tool could be trained on historical part performance data to assess the following: the estimated useful lifetime of a part the historical use rate of a part (such as hours or miles per day) macroeconomic conditions by region and industry that may affect trade-in timelines Adopting AI tools for core forecasting could help remanufacturers reduce core safety stock by 2 to 4 percent and save 3 to 5 percent in freight costs by reducing the cost of expedited shipping. AI tools could also help remanufacturers reduce overtime expenses, lose fewer sales due to stockouts, and ensure they have the parts that end customers need. Case study: Incentives for core availability. A top technology OEM struggled to match the regional availability of core […]

Masdar City’s Net-Zero Model Sets Sustainability Benchmark, but AI Holds Key for Aging Cities, Experts Claim

A new white paper from Masdar City highlights the UAE’s leadership in net-zero urban development. Energy experts say that net-zero strategies could also be applied to most cities worldwide, even when the biggest challenge is in retrofitting old existing buildings. Built as a purpose-driven net-zero city, Masdar eliminates the need for future retrofits by integrating energy efficiency from the start. However, decarbonization remains a challenge for most cities worldwide, where most buildings are decades old. Experts argue that AI-driven energy management could provide a viable solution, optimizing real-time energy use in existing infrastructure without the financial burden of deep renovations. “Masdar City demonstrates what’s possible when sustainability is built into urban planning from the ground up,” said Donatas Karčiauskas, CEO of Exergio, a company that implements AI-based energy efficiency tools in commercial buildings. “But most of the world’s cities don’t have that luxury. The question is: how do we bring net-zero strategies to older buildings without breaking budgets? AI is the most practical answer.” Buildings account for 40% of the EU’s final energy consumption and contribute 36% of its energy-related emissions. In Europe alone, 75% of buildings were constructed before 2000 and remain energy-inefficient, with 85-95% expected to still be in use by 2050–the net-zero deadline. This pattern is reflected globally, particularly in dense urban areas where outdated infrastructure dominates city skylines. While Masdar’s white paper highlights the importance of renewable energy, smart grids, and green building certifications like LEED, these approaches favor new developments and regions with access to significant capital. According to Karčiauskas, for cities with aging infrastructure, the challenge lies in improving operational efficiency rather than rebuilding from scratch. “Certifications like LEED are useful for ensuring new buildings meet sustainability benchmarks,” he noted. “But they don’t address how older buildings actually operate. Without real-time energy monitoring, sustainability […]

Horizons of growth in a challenging world

Image: Karsten Würth on Unsplash. “Over the longer term, the only way for the world to propel itself out of the low growth environment is through cooperation.” -Mirek Dusek The world is currently mired in a low growth environment, with the latest IMF forecasts projecting 2.8% global growth in 2023 and 3.0% in 2024 – rates which are well below the average experienced over the past decade. This is in the context of other ongoing fragilities including stubborn inflation, a global debt crisis, geo-economic rivalry, geopolitical conflict and vulnerabilities in the financial sector, among others. Despite this sobering outlook, or perhaps because of it, it is so crucial not to lose sight of avenues to relaunch growth and put us on a firm trajectory to new competitiveness and resilience. In this respect, I would like to point to three horizons of growth, for short-, medium- and long-term revitalization of the global economy: Reopened Asian economies Among the regions hardest-hit by the COVID-19 pandemic, Asia is emerging from a protracted period of muted economic activity and looks set to resume its role as the world’s growth engine. China’s economic opening up earlier this year has provided a much-needed boost to both the regional and global economy. The reopening of crucial Asian economies at large provides us with immediate growth markets which can serve to spur growth in the short-term, while also establishing a base from which to overcome the low growth environment moving forward. In comparison with other regions, Asia-Pacific is by far the brightest spot for economic growth at present, with the IMF’s latest estimates projecting the region to contribute 67.4% of all global growth in 2023, and with China alone contributing 34.9% of that total. The annual growth rate for the region is projected at 4.6% for 2023, representing […]

Carbon-neutral manufacturing is possible

Amid a slow political process on climate change, businesses globally must step up their efforts to reduce carbon emissions. Engineering and manufacturing can make an essential contribution to achieving net zero, as manufacturing plants, machinery, and sophisticated production processes are at the heart of global value creation everywhere. The good news is that we can help to significantly limit global warming and reach net-zero emissions, using the technology and know-how we already have. Three key priorities that will propel us more quickly on this journey – if we embrace them consistently: Focus all our efforts on minimising greenhouse gas emissions. Use all available levers for improvement, from the thousands of incremental refinements that add up to significant efficiency gains over time, to fundamentally designing and adapting large industrial plants and processes with the goal of climate neutrality. We will need to question established routines and scrutinise every aspect: can we minimise the amount of stainless steel or other raw material and still get the same performance? How can we reuse more of the waste we produce in production processes, or – even better – avoid it? And this line of questioning doesn’t stop within our own operations; we must encourage, or even require, our suppliers to do the same. This is critical given that a significant amount of greenhouse gas emissions are generated in the supply chain. We must put energy efficiency front and centre. There is no doubt that energy efficiency improvements will have to play a crucial role in putting the world on a net-zero pathway. In particular, heating and cooling require our immediate focus, as they account for a large proportion of energy consumption in processing plants – often between 50 and 90%. By deploying state-of-the-art heat pump technology, manufacturers can capture their waste heat from refrigeration and then boost the temperature to […]

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