Building Automation Boosts Productivity with Smarter Environmental Management

The Confederation of British Industry (CBI) reported that UK manufacturing output volumes fell in the quarter leading to June, continuing at a similarly steep pace to the previous quarter. While much attention is given to global headwinds and supply chain challenges, workplace environments are often overlooked. However, the internal conditions of facilities — such as air quality and energy use — can directly influence productivity. Karl Walker, market development manager at automation specialist Beckhoff UK, explains how building automation can help manufacturers address this productivity gap.

Like many other sectors, manufacturers face increasing pressure to drastically reduce emissions as the UK moves toward its net-zero goals. The Energy Savings Opportunity Scheme (ESOS), for example, requires companies to regularly audit energy consumption and carbon emissions.

In recent years, more companies have adopted smart monitoring and building automation systems to comply with these evolving standards. Beyond compliance, this technology can help identify ways to improve working environments — such as detecting overheated spaces that could cause drowsiness or pinpointing areas with poor air circulation that may lead to a buildup of CO₂ and other pollutants.

What to monitor
Environmental monitoring requires a balanced approach. Manufacturers need to track enough parameters to form an accurate picture of their facilities, yet sensors, gateways and other IoT technologies can be costly to install. It is therefore essential to focus on high-impact metrics — those that directly influence energy performance, operational costs, and overall productivity.

Indoor air quality (IAQ) is a particularly important factor. According to the Clean Air Fund, around 1.2 billion workdays are lost globally each year due to air pollution, a figure projected to rise to 3.8 billion by 2060. Employees exposed to polluted air are more likely to suffer from illness and reduced cognitive performance.

Monitoring particulate matter, volatile organic compounds (VOCs), and fumes released during production processes can help manufacturers take preventive action, such as installing filtration systems to mitigate health risks. Observing CO₂ levels, temperature, and humidity can also provide insight into factors that affect cognitive function and response times.

Making data actionable
Collecting data is only the first step — the real value lies in how it is used. Information can be gathered from various sources, including ventilation systems, HVAC units, and the building management system (BMS). While this data helps establish performance baselines, it can be fragmented and ineffective unless consolidated into a unified, intelligent platform.

Building functions can be seamlessly integrated into automation infrastructure. Beckhoff’s TwinCAT suite of automation tools, for instance, can transform almost any PC-based system into a powerful real-time control platform for building services. Manufacturers and facilities managers can collect and act on data from environmental sensors, occupancy detectors, and energy meters alongside standard control logic. If CO₂ levels rise, a smart system may automatically increase the flow of fresh air, improving air quality in affected areas.

By maintaining optimal environmental conditions, manufacturers can take proactive steps to reduce staff fatigue, enhance concentration, and boost overall productivity — particularly in facilities where precision tasks and long shifts are common.

As highlighted by the CBI report, UK manufacturing output has declined slightly in recent months. Improving environmental conditions within facilities could play a meaningful role in narrowing this productivity gap. Achieving this starts with maintaining a healthy, comfortable workplace that supports employee performance — not just through monitoring air quality and energy use, but by consolidating and applying data intelligently to drive continuous improvement.

www.beckhoff.com