Digital Processes in the Fast Lane: Safe and Efficient with Ethernet-APL

The digitalization of the process industry is progressing steadily – and with it come new requirements for communication infrastructure. As plants become increasingly complex and safety in hazardous areas remains a top priority, a key question arises: How can data be transmitted reliably, efficiently, and securely from sensors and actuators all the way to the control level? One answer is Ethernet-APL (Advanced Physical Layer).

At the first R. STAHL Ethernet-APL Technology Day, it became clear that this technology is far more than a theoretical concept. Experts, manufacturers, and users presented practical solutions, economic analyses, and live demonstrations – showing how Ethernet-APL is taking digital process automation to the next level.

The basis of every successful digital process plant is a robust network. Ethernet-APL demonstrates its capabilities through extensive practical testing that has been carried out since 2015. The focus is not only on transmission rates or latency, but also on whether the technology can operate reliably in complex plants with hundreds of field devices and long cable runs.

The results are convincing: even under extreme conditions, data transmission remains stable, and the integration of new end devices does not disrupt ongoing operations. The key lies in the combination of certified end devices, centralized management, and continuous diagnostics. This reduces downtime, lowers maintenance efforts, and increases flexibility – creating a solid foundation for future-proof digital process networks.

Particularly in hazardous areas, every installation must meet the highest safety standards. This is where the combination of Ethernet-APL and 2-WISE comes into play. While traditional solutions often required complex safety calculations and cumbersome re-dimensioning, this technology enables an almost automatic proof of intrinsic safety for the system.

Predefined device profiles and 2-WISE certified devices ensure that installations are intrinsically safe without requiring extensive individual verification. For planners and plant operators, this means secure, flexible, and easily expandable networks that meet the practical requirements of industrial plants.

Another key topic at the Ethernet-APL Technology Day was how Ethernet-APL can be integrated into existing process control systems. Siemens demonstrated how PROFINET over APL can be seamlessly integrated into SIMATIC PCS 7. Standardized device profiles and plug-and-play functionality enable new devices to be integrated into the network quickly and securely.

The advantages are obvious: plant operators can adopt modern field technologies without replacing their existing systems. At the same time, extended diagnostic and maintenance capabilities become available directly through the engineering system, significantly improving plant transparency and efficiency.

Ethernet-APL not only provides stability but also forms the basis for functional safety. As demonstrated in a presentation by HIMA, sensors can be connected directly via two-wire cables, data becomes instantly available in digital form, and safety profiles such as PROFIsafe operate reliably.

The technology enables secure digital communication without requiring certification of the entire infrastructure. The result is precise measurement data, centralized diagnostics, and easy integration of new sensors – representing a significant step forward for digital process automation.

Integrating classical IT technologies into industrial networks also introduces new challenges. Wherever Ethernet is used, typical IT attack vectors may arise. How these risks are managed determines whether the digitalization of process plants can be implemented securely.

A practical example shows how quickly security issues can emerge – and how concepts such as zero-trust architectures, digital device identities, and automated asset management are intended to prevent them. Ultimately, however, security must be integrated into the system architecture from the very beginning. Secure industrial communication is not a single product, but an ongoing process. PROFINET over APL already provides practical solutions in this area today.

In addition to technical feasibility, economic efficiency is also a decisive factor. Studies for new plants show that Ethernet-APL reduces cabling requirements, control room space, and installation effort, while commissioning becomes faster thanks to automated device detection. Day-to-day operations also benefit from parallel diagnostic and maintenance functions. The economic performance of Ethernet-APL in ongoing plant operations is currently being examined in a further study.

Practical experience from BASF confirms these findings: Ethernet-APL operates reliably in real plant environments, devices from different manufacturers can be integrated without difficulty, and the infrastructure becomes noticeably simpler. This is particularly evident in easier planning and significantly faster plant commissioning. As a result, the technology proves to be not only technically advanced but also economically attractive.

The Ethernet-APL Technology Day made one thing clear: Ethernet-APL is more than just a new network standard. It is an enabler of digital transformation that combines stability, safety, simple integration, and economic efficiency.

Whether for new plants or the modernization of existing systems, the technology offers clear benefits for operators, planners, and system integrators. They benefit from:

• seamless digital communication down to the sensor/actuator level
• simplified integration into existing control systems
• reduced installation and maintenance costs

Ethernet-APL is no longer a vision – it is already a reality today and forms the foundation for secure, digital process automation in the future.