The Rosemount 4051S pressure transmitter provides local real-time control, reducing the need for a separate device such as a programmable logic controller. Two configurable relay switches allow on/off control of pumps, motors, and other equipment, and can also issue alerts based on pressure, flow, totalized flow, level, volume, or module temperature.

“The Rosemount 4051S Pressure Transmitter is designed to provide exceptional versatility and performance, helping customers improve operations and expand their pressure measurement capabilities across a broad range of industrial applications,” said Nathan Stokes, vice president pressure products with Emerson’s measurement instrumentation business.

The Rosemount 4051S pressure transmitter is designed for demanding industrial processes and environments. It comes with a 20-year warranty and a 20-year stability specification. With a response time of 40 milliseconds and an 800:1 turndown ratio, the transmitter supports a wide range of applications while helping reduce the number of models required in inventory.

Advanced diagnostics monitor the electrical loop to identify potential issues. Plugged impulse line detection notifies plant personnel for corrective action and the transmitter can detect other conditions, including cavitation, using its built-in process intelligence. Calibration and diagnostic logs are available to support maintenance and root cause analysis.

The Rosemount 4051S features a larger backlit display than earlier models, showing warning messages, an always-on process variable and a customizable secondary area. The display supports seven languages and the user interface is designed to make operator interactions straightforward and minimize errors.

Bluetooth connectivity up to 50 feet (15 meters) allows plant personnel to access the transmitter without entering potentially hazardous areas. This connectivity supports more efficient operator rounds and simplifies configuration and troubleshooting. Operators are notified of devices that require attention and the AMS Device Configurator mobile app enables consistent management across all devices.

Guided proof testing and logging use a step-by-step process to streamline verification. Built-in proof testing confirms instrument functionality and supports operational efficiency and safety. The transmitter is certified to Safety Integrity Level 2/3 and IEC 61508. Partial proof testing can be performed in situ, allowing extended test intervals without applying an external pressure source.

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Energy is expensive, especially compressed air which can be eight times more expensive than electricity, with up to 50% of it being wasted through leaks. ���ϳԹ� machines wear. Systems are often oversized, taking more energy than required.

Research has shown that successful energy management programs start with measurement. Discover large consumers, leakages, incompetent use, and overdue maintenance. Use actual data to justify improvement investments and maintenance management.

One of the best ways to grow as an industrial manufacturing company is to save energy. Reducing consumption is best done through through compressed air and industrial gases monitoring.

“If you do this now, you will soon get it back as extra capacity,” said Pascal van Putten, director/founder of Delft-based VPInstruments. Measuring is knowing is admittedly a cliché, van Putten acknowledges, but in terms of content it is still extremely topical. “Nowadays there is no more room on the electricity grid for many manufacturing companies. It is therefore important to work collectively on energy savings,” he said. “We must do everything we can to ensure that companies can continue to grow in the future. I know examples of production companies that have hit a wall in this regard.” VPInstruments offers flow measurement systems for compressed air and industrial gases. The company develops and assembles in Delft and exports to approximately 70 countries worldwide.

Speed up production

VPInstruments’ customers can be found in various sectors, such as the food, glass, steel, automotive, high-tech, electronics, and chemical sectors. “Every manufacturing company has a compressed air component. Think of controlling valves on the assembly line, machines that make packaging, or blowing granules in light chemicals,” van Putten said.

For example, at a chocolate factory, targeted energy management could achieve annual savings of 125,000 euros. Van Putten noted that assembly and packing machines producing the chocolate had a great deal of leakage. A partner of VPInstruments used one insertion type flow meter and measured in several places in the factory, both supply and demand side.�� “During breaks the machines were on standby, but the consumption was still 50% compared to nominal,” he said. “We were able to trace where it leaked. You can walk through the factory with a leak gun — that’s nice but expensive equipment — but it takes a lot of time if you must do this in several buildings.”

The ultrasonic leak gun revealed leakages throughout the entire factory. However, the biggest find was the leaks in the cacao presses. Once they fixed those, the pneumatic press opened and closed faster.

Machine cycles also had slowed down in this chocolate factory. After VPInstruments’ technology was installed, the pneumatic press opens and closes faster again, resulting in significantly higher production and fewer malfunctions. The latter has a positive effect on the atmosphere in the workplace.

Less is more

Companies can also fine-tune the efficiency of compressed air systems by combining the right types of compressors. This can make a difference of tens of percent, Van Putten continued. The payback period for the investment in one or more flow sensors is generally less than a year, he said. “’Less is more’ is the trick with sensors. We use the art of omission and are not in favor of filling a factory with sensors. We work top-down: first we do the main line and then we roll it out like a pyramid. That is by far the smartest and most effective approach.”

For industrial gasses, the payback time of a flow sensor is even shorter. While compressed air costs a few cents per cubic meter, gases such as argon, nitrogen or oxygen cost a few euros per cubic meter. “For example, welding uses argon and CO2. Hoses connected to the welding torch often leak,” he said. “You can’t smell that, and I know a factory in the United States where the leaks were in the barrels. We are helping more and more companies with managing these industrial gasses.”

Using flow meters for leak management

Flow meters are essential tools for quantifying and managing compressed air leaks in industrial facilities. One common method is to measure air consumption during non-production periods. Many factories are idle over weekends yet still observe compressor activity and air usage, clear indicators of leakage. By monitoring flow during these downtimes, the volume of leaks can be effectively estimated.

In facilities operating 24/7, establishing a baseline consumption is key. Install a flow meter to monitor overall air usage, then conduct an ultrasonic leak audit to identify and repair leaks. After repairs, the reduced air consumption becomes your new baseline. Any future increase in consumption may signal new leaks.

To localize issues more precisely, place flow meters in different production zones. This allows you to compare air usage by area, identify anomalies, and focus your ultrasonic inspections where they are most needed. This zone-based approach turns leak detection into a continuous and data-driven process.

Monitoring the right set of KPIs, such as efficiency, pressure loss, and leakage, is a must-have for any energy manager or plant owner. VPInstruments’ uses its VPFlowScope M flow meter, which provides a window into your overall system. If consumption is significantly higher than normal or you see a pressure event, you need to look at your production lines or talk to operators in the plant. If dew point is off, fix/service the dryer or check if it is properly sized.

An inexpensive battery

Van Putten has an interesting idea for factories with high peak consumption. “If such companies invest in compressed air storage, you could run the same production with smaller compressors. This relieves the burden on the local electricity grid, and you do a service not only to yourself but also to your neighbor. There are parties — including a start-up in the Netherlands that is active in this field — that store compressed air in salt domes underground. That is a relatively cheap battery. But it can also be smaller with local storage tanks in your own compressed air system.”

For example, suppose that as a producer in Rotterdam, you do not need compressed air all the time or you want to purchase the electricity for your compressed air cheaply. Then you run the compressor when the electricity price is low. With the help of your storage tank, you can manage the peak load better. Investment in storage tanks is not expensive, he said.

VPInstruments

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Visitors to the Emerson booth in Hall 11, Booth C30, will learn how companies of any size can apply a Floor to Cloud approach to drive sustainable growth, maximize performance quality and unleash workforce productivity for immediate and long-term success.

Located in the Automation, Motion & Drives area, booth C30 will feature immersive demonstrations and displays. This interactive hub will showcase how products from ASCO, Aventics, Branson, Movicon, PACEdge and PACSystems brands combine to form intelligent solutions that transform operations across the factory floor and deliver ongoing value.

Scheduled presentations from Emerson experts in the Innovation Theater give visitors the opportunity to solve complex industry challenges and pathways to achieve a wide range of goals. Topics include driving sustainable growth, energy savings and efficiency, and proportional pressure control in robotic applications, as well as real customer success stories.

Product highlights

Aventics Series XV pneumatic valves — Next-generation Aventics Series XV pneumatic valves offer greater range and flexibility with higher flow rates to give original equipment manufacturers greater design flexibility and scalability when engineering handling systems or automation solutions. Designed with interoperability in mind, the new Series XV valves include a broader range of configurations and use proven core valve Aventics technology. Providing higher flow rates in a compact valve package, Series XV valves enable more efficient and flexible pneumatic system performance while offering products customized for specific markets, including factory automation, automotive and tire, food and packaging applications. Series XV valves include the XV03, providing flow volumes up to 350 liters NL/min, and the XV05, which can provide up to 1000 NL/min.

Aventics Series AF2 Flow Sensors – These sensors have helped plants around the world successfully reduce compressed air consumption and improve energy efficiency. By monitoring air consumption in pneumatic systems, AF2 sensors enable rapid intervention if leaks occur, helping optimize energy consumption, reach net-zero targets, prevent machine downtime and reduce costs. Emerson also offers a high-flow model of this advanced sensor that propels compressed air monitoring beyond individual machines to benefit larger air lines and systems. This expanded capability allows users to easily optimize energy consumption across an entire packaging facility and improve overall plant sustainability.

Energy Manager – Designed to help manufacturers cut energy costs and carbon emissions by up to 30%, the new Energy Manager��solution from Emerson transforms energy challenges into opportunities. Machine tools are energy-intensive, even when idling. This plug-and-play system offers real-time electricity monitoring to identify and minimize waste, optimizing energy use and boosting operational efficiency. With quick setup and intuitive operation, the Energy Manager provides detailed insights into energy consumption and operating costs, allowing plant managers to reduce idle consumption and peak loads. This application can also be used in conjunction with the Compressed Air Manager solution, offering a scalable, comprehensive view of energy and utility consumption.

Software solutions – Today’s manufacturing facilities require modern automation technology that can readily adapt and meet changing production and operational requirements. Success increasingly depends on advanced SCADA solutions that seamlessly integrate diverse systems and assets, often over wide geographic areas, while maintaining robust cybersecurity. The Movicon industrial software platform delivers the next-generation of SCADA/HMI connectivity and operability through modular, scalable and secure interfaces. The innovative suite of tools includes Movicon Pro.Lean, which harvests real-time production and performance data that can be used to reduce waste and increase profitability, and Movicon Pro.Energy, which measures energy consumption and can guide decisions around sustainability and efficiency strategies.

Programmable automation control systems – Industrial operations today need a flexible, scalable and affordable approach to modernization. PACSystems controllers add a new dimension to industrial control and automation, allowing production optimization and monitoring capabilities in the widest range of process and discrete industrial environments. These automation control solutions bring control intelligence with a real-world approach to identify and predict impending failures, enable proactive maintenance, boost cyber security and customize data acquisition and analytics — so businesses can minimize downtime and handle market changes with agility. Core Emerson automation control innovations include the PACSystems RX3i CPL410 and CPE330 controllers, which offer extensive flexibility for a range of applications, as well as the RSTi EP I/O, which combines powerful controller technology in a modular, compact form factor with a full range of slice I/O to maximize productivity.

Cylinders and actuators – Emerson cylinders and actuators are designed to exceed performance standards and stay within footprint, no matter how compact or demanding the application. The comprehensive range of high-quality cylinder technology meets the demands of modern automation applications. Whether designs require pneumatic, electric or hybrid solutions, Aventics cylinders and actuators increase the overall performance and flexibility of machines. Core innovations include the Aventics series SPRA electric rod-style linear actuator, which is an efficient, high-performance actuator that offers improved load capacity, accuracy and reliability. The Aventics CylinderFinder is an easy-to-use online tool that makes it simple to find the perfect cylinder for an application.

Edge devices – Emerson edge devices combine the best deterministic controllers on the market with secure, nondeterministic controllers for analytics and machine learning algorithms to proactively optimize business outcomes. These rugged devices are designed for remote industrial areas and equipped with our vendor-agnostic PACEdge software to safely run nondeterministic applications. This reduces latency and meets all application performance requirements.

Compressed Air Manager – The Compressed Air Manager provides visualization and benchmarking for compressed air and gas consumption for a machine, for a production line or across multiple sites. A predesigned, edge-enabled cabinet solution serves as a foundation to connect and power monitoring across multiple machines and lines via Aventics Series AF2 smart air flow sensors. The Compressed Air Monitoring App, which comes pre-installed on the edge device, is easily configurable and continuously monitors and analyzes data coming from the sensors. The Compressed Air Manager transforms available data via an embedded dashboard with KPIs where operators can easily visualize consumption trends, costs, benchmarks and CO2 impact. This data empowers users with greater insights to help reduce energy costs, improve sustainability and streamline maintenance.

Material joining and cleaning technologies – The quality of automotive parts, medical devices, electronic components and other essential products depends on high-performance material joining and cleaning technologies. Backed by innovation and worldwide support, Branson technologies from Emerson include ultrasonic welding for plastic and metal, as well as laser, vibration, infrared & spin welding and staking for plastic as well as ultrasonic cleaning solutions. Core welding innovations include the Branson GSX-E1 ultrasonic welder, which produces clean welds in minimal time with highly uniform joints for greater consistency and operational efficiency.

Aventics feeding & handling solutions – Aventics feeding and handling solutions provide manufacturers with a broad portfolio of standardized systems, modular assemblies and advanced components for plug-and-play productivity. The innovative Aventics feeding portfolio features unique vibration force compensation technology and offers everything from proven vibratory feeders, refilling devices and control units to flexible feeding technology components. With standardized components in a modular system, station layouts can be adapted exactly to meet application requirements, minimize gap dimensions and improve precision of feeds and availability of the feeding system. Aventics handling portfolio offers more than 20 standardized handling systems that can be configured online, optimized and delivered as plug-and-play solutions for demanding pick-and-place applications. Combining high-speed performance, consistent precision and long service life, Aventics handling systems help manufacturers shorten cycle times, boost throughput and lower costs in handling applications on the production line.

Emerson

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