In an exclusive interview to Indian Chemical News, G. Balaji, SVP, Energy Industries, ABB India talks about how automation is transforming chemical manufacturing, role of automation in improving safety in hazardous process environments, integration of automation and digitalization, ABB offerings. Excerpts of the interview: 

How is automation transforming chemical manufacturing?  

In an industry where every second and every variable counts, automation is the backbone of modern chemical manufacturing. At its core, automation systems bring stability, safety, and precision to highly variable and sensitive chemical processes. With automation technology, we can monitor and control critical parameters in real-time, ensuring operational efficiency and safety, which is crucial when manufacturing in hazardous areas. 

In continuous operations such as polymer or petrochemical production, automation ensures that even micro-variations are corrected instantly, driving higher yields and reducing downtime. In the case of batch operations, where precision and flexibility are essential, intelligent automation can unlock new levels of efficiency. Today’s advanced batch management systems, integrated with real-time analytics and AI, enable adaptive control across multiple product lines. Recipe changes can now happen in minutes, with complete traceability, helping manufacturers maintain quality at every step. Currently, the industry is also exploring the automation of recipe creation directly from ERP systems.  

As market demand keeps evolving, automation gives flexibility to scale up or shift direction and change products without losing consistency. It’s not just about performance anymore; it’s about getting to market faster, cutting out inefficiencies, and staying ahead in a fast-paced industry. 

What’s the role of automation in improving safety in hazardous process environments? 

In hazardous areas, automation is the invisible shield that protects what matters most – people, assets, and uptime. By enabling real-time monitoring and control of key parameters, it significantly reduces the need for manual intervention in high-risk areas. Advanced automation systems can detect anomalies early, trigger alarms, and even initiate safe shutdown procedures, ensuring a swift and controlled response. 

Take, for example, a chemical plant handling flammable or toxic substances. A safety-integrated automation system continuously tracks critical variables. If any parameter exceeds its safe limit, the system can immediately isolate the affected area and shut it down to prevent escalation. When combined with predictive maintenance solutions, automation can also flag potential issues before they lead to equipment failure.  

How can integration of automation and digitalization in chemical manufacturing help in decarbonisation? 

Automation systems ensure that processes run at optimal efficiency, minimizing waste and energy use. At the same time, digitalization gives operators the data and insights needed to make smarter, faster decisions, whether it’s optimizing raw material usage, reducing unplanned downtime, or identifying carbon hotspots across the value chain. Together, they form a powerful duo, enabling more agile, and sustainable operations, ones that align with the industry's long-term decarbonization goals. However, the real impact lies not just in adopting these technologies, but in how strategically and effectively they are applied to drive continuous improvement and adaptability. 

What is ABB’s offering in the chemicals segment? Can you share examples of how ABB technology has helped chemical/petrochemical plants? 

At ABB, our portfolio is designed to meet the unique demands of both continuous and batch chemical production. From Distributed Control Systems (DCS) like ABB Ability System 800xA to Manufacturing Execution Systems that connect plant operations with enterprise systems, and Batch Management Systems designed for precision and flexibility, we cover the full spectrum.  

ABB’s DCS minimizes manual interventions, reduces downtime, and maintains consistent product quality all along ensuring that the production intelligence is available and secured within the system. Our Remote I/O solutions simplify wiring, speed up commissioning, and enable modular automation, ideal for facilities producing small or custom batches. We also provide smart electrification, power management, cybersecurity, and advanced digital solutions to support predictive maintenance and optimize asset performance. 

Our systems are known for their reliability in high-stakes environments. For instance, we helped an agrochemical manufacturer to control over 100 reactors through the ABB Ability platform at their largest facility in India.  

How is ABB leveraging AI and machine learning in chemical manufacturing? 

In many plants, AI is powering predictive maintenance, detecting early signs of wear in equipment like pumps and motors to reduce unplanned downtime. Solutions like ABB Ability Genix, brings together data from across the plant, helping manufacturers monitor equipment health, improve performance, and reduce emissions. 

Our APM suite, i.e. Genix APM, uses AI & ML algorithms to perform pattern recognition, helps in identifying operating anomalies and predicting potential faults before they lead to unplanned downtime. We are helping operators shift from reactive maintenance practices to predictive maintenance which provide tangible benefits in terms of improving equipment utilization, extending equipment service life, safety and performance in a cost-effective manner.  

With platforms like Genix APM Copilot, we’re taking it a step further by bringing generative AI into the equation, enabling seamless processing and analysis of data from diverse sources, including shop floor operations, operator interactions, enterprise systems, unstructured data and metadata. With a strong focus on data security and governance, Genix Copilot ensures a trusted and efficient AI-driven ecosystem for industrial operations. 

Ultimately, our goal is to help customers by integrating AI and ML across our offerings, digital platforms, and asset management solutions to create a more intelligent, autonomous, and sustainable chemical manufacturing environment.