Wireless Technologies Driving Digitalization in the Process Industries

Modern wireless communication systems are becoming increasingly important in the process industries, enabling numerous applications that significantly enhance efficiency, transparency, and operational safety. Two main fields are currently driving this development: digital support for maintenance and operations personnel, and wireless Industrial IoT applications for continuous condition monitoring. Both rely heavily on robust wireless infrastructure, especially in the large-scale environments typical of chemical, pharmaceutical, and oil & gas facilities.

One key application is the concept of the “Mobile Worker.” Modern smartphones and tablets allow maintenance staff to access repair instructions in real time, document inspections digitally, and communicate via voice or messaging tools. They also support critical safety functions such as emergency alerts and worker localization. In times of increasing skilled-labor shortages, such digital tools help organizations significantly improve labor productivity and ensure efficient workflows across large facilities.

These applications depend on reliable wireless networks. Technologies such as WiFi and increasingly 5G private networks form the backbone of modern industrial connectivity. However, deploying such networks requires the careful definition of use cases to determine coverage, bandwidth, device requirements, and safety needs.

Once requirements are clear, detailed network planning must follow, including radio frequency simulations, component selection, and installation strategies.

In process industries, another demanding factor comes into play: hazardous areas requiring explosion protection. Only equipment that is specially designed or protected may be used in these zones, ensuring that the devices cannot become an ignition source.

For mobile devices like smartphones and tablets, specialized explosion-protected models are available. The challenge lies in selecting the correct protection level for each zone. Mobility introduces additional complexity: portable devices might inadvertently be taken into zones for which they are not certified. For this reason, many operators prefer to select devices with the highest required protection level to avoid such risks.

An even more complex challenge arises when installing the wireless infrastructure itself. Only a very limited range of Ex-certified WiFi access points or 5G devices is available on the market. As a result, operators sometimes attempt to project wireless signals from outside into hazardous areas—but physical barriers such as walls, steel structures, or long distances often make this approach insufficient.

The practical solution is to install standard network devices within the hazardous area—enclosed in suitable explosion-protected housings. This is where solutions from specialized providers such as R. STAHL play a key role.

Using Ex-certified enclosure systems, such as the 8265 series in flameproof “d” protection for Zone 1 or the 9851 series with “nR” protection, standard WiFi access points or 5G picocells can be safely operated in hazardous locations. The enclosure provides complete explosion protection, eliminating the need for the network device itself to carry Ex-certification. At the same time, this approach allows rapid replacement of network technology—an important advantage given short innovation cycles. Thus, modern connectivity standards like WiFi 6 or 5G can be deployed without restrictions, even in demanding industrial settings.

R. STAHL complements these infrastructure solutions with a comprehensive portfolio that includes mobile devices and engineering services, offering customers a true one-stop shop for project-specific explosion protection.

The wireless enclosure system can also be used to integrate wireless IIoT sensors or permanent condition-monitoring systems, even in existing brownfield plants.

In conclusion, wireless communication is essential for the digital transformation of the process industries. Whether enabling mobile workers or generating additional data for process optimization, wireless technologies increase efficiency and transparency. With the right solutions, explosion protection is not a barrier but a manageable and integral part of modern industrial communication.