AS3_2025

Aprile 2025 Automazione e Strumentazione Tecnica 92 CONTROLLO cess automation relies on centralized control systems that deeply integrate into plant control layers, making changes or expansions complex and costly. MTP, however, follows a modular approach: modules operate as independent units with their own control systems, integrating into the overall plant via standardized interfa- ces. This provides numerous advantages for the industry. During the planning phase, MTP significantly reduces development time by using pre-confi- gured modules. Studies indicate that planning time can be reduced by up to 60% since many processes are already standardized [5]. Engine- ering firms no longer need to configure each component individually but can rely on a library of standardized modules, saving time and mini- mizing errors. During commissioning, another major advan- tage becomes evident: traditional automation systems require extensive integration into the overarching control system. In contrast, MTP modules can be directly integrated into the Pro- cess Orchestration Layer (POL), accelerating commissioning by up to 75% since control logic is pre-defined and does not require extensive programming [6]. Even during operation, MTP enhances effi- ciency. Changes to production lines, which tradi- tionally resulted in long downtimes, can now be implemented swiftly due to the modular appro- ach. New processes can be added without recon- figuring the entire automation system, making production facilities up to 90% more flexible and adaptable to changing market demands [7]. From an economic perspective, MTP adoption leads to significant cost savings. The reusability of modules can reduce capital expenditures by up to 50%, while engineering efforts decrease due to pre-defined automation functions at the module level [1]. Furthermore, the manufactu- rer-independent implementation ensures that companies are no longer locked into a single automation provider, increasing flexibility in technology selection [2]. MTP also simplifies the modification and expan- sion of existing plants. While traditional produc- tion facilities are often difficult to scale, MTP enables seamless integration of new modules, allowing companies to adjust production capa- cities as needed without excessive retrofitting costs. Additionally, individual plant sections can be shut down or removed without disrupting the overall production process [8]. A key advantage of MTP is its future-proof nature. While traditional automation systems are rigid and difficult to adapt to new requirements, MTP allows for gradual upgrades of plants. New modules can be added or existing components replaced without major modifications to the con- trol system, making the standard particularly attractive for companies seeking long-term fle- xibility [3]. Successful MTP Applications A compelling demonstration of MTP’s capa- bilities took place at the Achema trade fair in 2022. Over 30 companies showcased the latest MTP technologies with fully functional demon- strators and products. Unlike previous exhibi- tions featuring conceptual presentations, this time market-ready solutions were demonstrated, embodying the plug-and-produce philosophy of modular automation. Modules from various manufacturers seamlessly integrated with con- trol systems from different suppliers and were directly operated from multiple Process Orche- stration Layers (POL). A notable example of MTP’s success is Merck, which has extensively used MTP to optimize modular production. Merck employs over 300 process modules (PEAs) across laboratories, pilot plants, and production. This implementation has reduced development and integration times by up to 50%. Particularly in the regulated pharma- ceutical environment, MTP offers crucial com- petitive advantages, as new production processes can be implemented more quickly while meeting stringent regulatory requirements[9]. Another leading example is Fink Chem+Tec , a manufacturer of dosing modules that, through collaboration with Semodia , evolved from a sim- ple pump supplier into a solution provider. Recog- nizing early on that process module manufactur- ers needed a software solution to make their prod- ucts MTP-compatible, Semodia developed the MTP-ControlEngine. This C++ software devel- opment kit (SDK) enables MTP-compliant con- trol behavior according to VDI/VDE/NAMUR 2658, running on various platforms such as x86, AMD64, and ARM. It also includes an integrated OPC UA server for seamless POL integration[1]. Fink Chem+Tec became the first manufac- turer to present a fully MTP-implemented dos-