Tailor-made solutions for a more sustainable industry
Innovation, efficiency and environmental commitment through custom-built machinery
Sustainability has become one of the major challenges – and also opportunities – of the 21st century for the industrial sector. Far from being a passing trend, environmental pressure, regulatory changes and the growing demand for responsibility from consumers and investors are transforming the way production is conceived. Companies are no longer focused solely on improving productivity: they must now do so responsibly, reducing their environmental impact and optimising the use of resources.
In this context, the customisation of industrial machinery emerges as a key solution. Beyond operational efficiency, adapting machinery to the specific needs of each process makes it possible to reduce material waste, minimise energy consumption and extend the service life of equipment. In other words, customisation not only improves performance, but also moves industry towards a more sustainable, intelligent and competitive production model.
At IFAMAC, we firmly believe that there is no sustainability without customisation. Every plant, every sector and every client faces different challenges. That is why we design tailor-made solutions that combine engineering, technology and environmental commitment. From rotary screens adapted to the characteristics of the material, to rubber feeders designed to reduce energy consumption, our machines help transform industry from within, process by process.
Industrial sustainability: from discourse to action
According to PwC’s State of Climate Tech 2023 report, only 25% of large industrial companies have implemented structural measures to reduce their environmental footprint. However, pressure is increasing: through the Green Deal and the 2030 decarbonisation regulations, the European Union requires a reduction of at least 55% in emissions compared to 1990 levels.
Spain, for its part, is making steady progress. The Ministry of Industry and Tourism reports that more than 60% of medium-sized companies are already transitioning towards cleaner processes, with the use of more efficient and adapted machinery being one of the key factors.
At this point, technological customisation becomes a competitive advantage. It is not simply about fitting a machine to a specific space or capacity, but about designing solutions that improve performance, reduce energy consumption and minimise material waste from the very outset.
Efficient technology driving change
At IFAMAC, we understand that every production process requires its own solution. Below are some examples of how customisation can have a direct impact on industrial sustainability:
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Customised rotary screens: In industries such as structural ceramics, a rotary screen adapted to the type of clay or waste can increase classification efficiency by up to 35%, reducing the volume of discarded material. Improved particle separation also facilitates the reuse of by-products, optimising the material life cycle.
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Rubber feeders: These provide controlled and continuous feeding, preventing excessive use of raw materials and reducing peaks in electricity consumption. Their modular and robust design extends equipment lifespan, reducing the need for frequent replacements and the environmental impact associated with manufacturing new components.
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Screw conveyors: Designed for transporting solid products with moderate particle size such as aggregates, coal, biomass or ash. Manufactured in carbon steel or stainless steel, they can incorporate cooling jackets to improve the thermal efficiency of the process. Their enclosed structure also helps reduce dust emissions to the surrounding environment.
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Redler-type conveyors: Mechanical transport systems using drag paddles in a metal trough. They are characterised by their cleanliness and tight sealing, making them ideal for processes requiring enclosed environments, such as the transport of biomass, sludge or ash. Their hermetic design also makes them suitable for operation under flooded conditions, reducing particle dispersion and improving industrial safety.
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Biomass accumulating rake: Designed with dual functionality: it accumulates biomass in a linear hopper after truck unloading and feeds it efficiently into the subsequent conveyor. This enables more orderly fuel management in biomass plants, preventing irregular build-ups and losses due to evaporation or dispersion.
Impact data: before and after
Two decades ago, the use of standard machinery without digital control was the norm. Today, more than 45% of new industrial installations in Europe already require customised equipment with low energy consumption and the ability to integrate with IoT platforms.
A study by consultancy firm McKinsey indicates that industries investing in solutions adapted to their processes have reduced industrial waste by an average of 30% and energy consumption by 20%. This evolution also translates into economic savings: lower maintenance costs, fewer production stoppages and greater operational efficiency.
Furthermore, by combining these solutions with automation systems and intelligent sensor technology, it is possible to make real-time decisions, optimise every stage of the process and achieve energy savings of between 10% and 20%, according to data from the International Energy Agency (IEA).
Looking to the future: personalised industry, sustainable industry
The future of industry lies in intelligent and sustainable efficiency. By 2030, it is estimated that 70% of medium-sized and large industrial companies in Europe will require machinery specifically designed for their processes, as part of their commitment to emissions reduction and the circular economy.
At IFAMAC, we are convinced that sustainability is not a limitation, but a driver of innovation. That is why we will continue to develop tailor-made solutions that address present and future challenges, reducing the environmental impact of industry without compromising competitiveness.
Industrial Automation in Spain: Innovation and Efficiency in the 21st Century
The advancement of industrial automation in Spain
Industrial automation has radically transformed production in Spain, driving efficiency, safety and competitiveness across numerous sectors. Over the past two decades, the integration of automated systems has enabled the manufacturing industry to improve performance, adapt to market demands, and meet the strictest quality standards.
According to data from the International Federation of Robotics (IFR), Spain is the fourth European country in terms of industrial robot density, with more than 180 units per 10,000 manufacturing employees. This trend reflects the steady growth of automation in the Spanish industrial landscape, particularly in key sectors such as structural ceramics, bulk material transport, and the food industry. Furthermore, government initiatives and R&D investment have supported the development of advanced technologies, allowing a progressive integration of automation across all types of companies.
Benefits of industrial automation
The adoption of automated technologies in Spanish industry offers multiple advantages:
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Efficiency and productivity: Automation reduces production times and minimises human errors, allowing for a significant increase in output.
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Cost reduction: By optimising processes and decreasing material waste, companies can improve profitability.
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Workplace safety: The implementation of robots and automatic systems reduces workers’ exposure to hazardous or repetitive tasks.
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Adaptability to demand: Automated systems enable rapid adjustment to market fluctuations and specific customer requirements.
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Sustainability: Automation contributes to more efficient resource use, lowering energy consumption and minimising the environmental impact of industrial processes.
Applications of automation in key sectors
Structural ceramic industry
The Spanish ceramic sector is a global reference, particularly concentrated in the Valencian Community. Automation has optimised the production of bricks and structural materials, improving kiln efficiency, drying systems and product classification. Technologies such as machine vision and collaborative robotics have reduced waste and enhanced the final product quality. Additionally, automated control systems guarantee greater energy savings and lower CO₂ emissions, a key factor in transitioning towards more sustainable production.
Bulk and solids transport
Efficient management of bulk materials, such as cement, flour or plastics, increasingly relies on automated solutions. Pneumatic and mechanical transport systems, combined with IoT sensors, enable precise flow control, reducing loading and unloading times while minimising losses. Predictive technology in inventory management also prevents unnecessary production stoppages and optimises industrial logistics.
Biomass transport
Automation is also transforming the biomass transport sector, a crucial industry in the energy transition. The implementation of mechanical and pneumatic conveyors optimises the handling of organic waste and woody materials, ensuring a constant and efficient flow in renewable energy plants. Automated systems also monitor moisture and material quality in real time, enabling more efficient and sustainable combustion. This innovation has contributed to a 20% reduction in operational costs and significant improvements in energy efficiency at biomass plants in Spain.
Food industry
In a sector where safety and quality are paramount, automation has revolutionised packaging, labelling, and quality control processes. The deployment of robots on production lines optimises food handling, ensures higher hygiene standards, and reduces contamination risks. Moreover, artificial intelligence in product inspection allows defects to be detected with unprecedented precision.
In Spain, the growing demand for processed food has driven the adoption of automated solutions to improve traceability and ensure compliance with European food safety regulations. Automation has also enabled large-scale food production without compromising product quality or safety.
Challenges and future prospects
Despite its advantages, industrial automation in Spain faces challenges such as the need for greater digital skills training and the adaptation of SMEs to these technologies. Currently, 70% of large industrial companies have already integrated some form of automation, whereas only 30% of SMEs have done so, according to the Ministry of Industry, Commerce and Tourism.
However, with incentive programmes such as the Kit Digital and the EU’s Next Generation funds, Spanish companies have a unique opportunity to modernise and strengthen their position in an increasingly demanding global market.
In conclusion, industrial automation is not only the present but also the future of industry in Spain. Investing in these technologies is essential to enhance competitiveness and ensure sustainable growth across sectors. Digitalisation and automation go hand in hand in transforming Spanish industry, enabling companies to evolve towards smarter, more efficient and sustainable production models.
Industrial automation and workplace safety: How to ensure a safe working environment
In this article, we will explore how industrial automation can improve workplace safety in the plant by reducing exposure to hazardous tasks and minimising human error. We will highlight key safety measures and best practices to ensure a safe and efficient working environment in the production facility.
Industrial automation for a safer workplace
Industrial automation has revolutionised the way we operate manufacturing plants. By replacing dangerous and repetitive tasks with automated systems, we significantly reduce risks for workers and enhance workplace safety.
Reducing Risks in Hazardous Tasks
Industrial automation plays a crucial role in preventing workplace hazards associated with dangerous tasks. Activities such as handling heavy objects, exposure to high temperatures, or working in hostile environments can be assigned to intelligent machines and robotic systems. By minimising direct worker exposure to these hazards, the likelihood of accidents and serious injuries is drastically reduced.
Unlike humans, machines are not affected by fatigue, distractions, or tiredness, resulting in consistent, high-quality production. The precision in task execution reduces errors and minimises the risk of accidents caused by human mistakes.
Minimising Human Error in the Production Plant
Human error is a constant concern in industrial environments. With industrial safety measures and automation, many processes become precise and free from human error. This ensures more consistent production and decreases the likelihood of accidents.
Another key benefit of industrial automation is the ability to monitor and control systems and processes remotely. Operators can oversee operations from a safe location and respond quickly to any hazardous situations. Remote intervention in dangerous scenarios further enhances workplace safety and improves emergency response efficiency.
Key Safety Measures in Industrial Automation
To achieve a safe working environment in an automated plant, it is essential to implement safety measures that protect employees, optimise operational efficiency, and prevent risk situations. Some of the most important measures include:
Ergonomic Machinery Design
Ergonomic design in industrial machinery is critical for ensuring worker safety and wellbeing. At IFAMAC, we understand the importance of this factor and strive to develop industrial machinery that prioritises ergonomics at every stage of design.
Safety Barriers and Restricted Zones
The installation of physical barriers and clearly defined restricted access areas are fundamental in an automated plant. These barriers protect workers from unintended interactions with operating machinery, preventing accidents and injuries. Clear protocols for access and exit must be established, ensuring that only authorised personnel can enter these areas.
Emergency Stop Systems
Emergency stop devices should be strategically located throughout the plant. These allow operators to immediately halt machinery in case of any hazardous or emergency situation. It is crucial that these devices are easily accessible and clearly marked to guarantee a rapid and effective response.
Safety Sensors and Detection Systems
Installing safety sensors and detection systems is essential for safe operations. These devices can detect the presence of objects or people in hazardous areas and automatically stop or slow machinery as needed. Sensors can also monitor parameters such as temperature, pressure, or liquid levels to prevent dangerous situations.
Human-Machine Interaction Safety
Interaction between workers and automated machinery must be carefully designed to minimise risk. Implementing control systems with intuitive interfaces and clear signage helps operators understand machine operation and prevents misunderstandings or incorrect actions that could jeopardise safety.
Ongoing Safety Training
Continuous safety training for all employees is one of the best practices for ensuring a safe working environment in an automated plant. Workers must be familiar with established safety measures, know how to operate machinery correctly, and be prepared to act in emergencies. Training should also include periodic drills to practice evacuation and response procedures.
Monitoring and Preventive Maintenance
Constant monitoring of automated machinery is key to detecting potential failures or safety issues. Additionally, conducting regular preventive maintenance ensures machinery operates correctly and minimises risks. At IFAMAC, our excellent after-sales service guarantees that, if required, we will reach the plant location within 48 hours.
Best Practices for a Safe Environment
Beyond the measures already mentioned, several good practices help maintain a secure and protected workplace:
Safety Culture in the Workplace
Fostering a safety culture across the organisation is essential to protect workers and ensure their wellbeing. This involves raising collective awareness about the importance of workplace safety and promoting individual and group responsibility in accident prevention. Employees should feel empowered to report any risk situations they identify and actively participate in proactively identifying potential hazards. Recognising and rewarding safe practices also motivates employees to maintain high safety standards in their daily routines.
Technological Updates for Industrial Machinery
Technology in industrial automation is constantly evolving. Staying up to date with the latest innovations and solutions in automation and safety is essential for maintaining a safe plant environment. Adopting more advanced technologies, such as more precise sensors, real-time monitoring systems, and enhanced safety devices, ensures a faster and more effective response to potential hazards. Additionally, staying informed of the latest industrial safety trends provides a competitive advantage in terms of efficiency and compliance.
Periodic Risk Assessments
Workplace risks can change over time due to factors such as company growth, the adoption of new technologies, or the development of new processes. Conducting periodic risk assessments is essential to identify emerging threats and areas that require safety improvements. These assessments should involve safety experts along with active participation from employees working directly in the plant. The results allow for implementing additional preventive measures and updating existing safety practices to maintain a safe work environment adapted to evolving circumstances.
At Ifamac Technology, we understand the importance of industrial automation in enhancing workplace safety in manufacturing plants. By reducing exposure to hazardous tasks and minimising human error, our automated industrial machinery ensures a safe and productive working environment. Implementing key safety measures and following best practices, along with fostering a strong safety culture, are fundamental steps to ensure workers are protected while contributing to the company’s success.