TY - JOUR A1 - Eifert, T. A1 - Eisen, K. A1 - Maiwald, Michael A1 - Herwig, C. T1 - Current and future requirements to industrial analytical infrastructure—part 2: smart sensors N2 - Complex processes meet and need Industry 4.0 capabilities. Shorter product cycles, flexible production needs, and direct assessment of product quality attributes and raw material attributes call for an increased need of new process analytical technologies (PAT) concepts. While individual PAT tools may be available since decades, we need holistic concepts to fulfill above industrial needs. In this series of two contributions, we want to present a combined view on the future of PAT (process analytical technology), which is projected in smart labs (Part 1) and smart sensors (Part 2). Part 2 of this feature article series describes the future functionality as well as the ingredients of a smart sensor aiming to eventually fuel full PAT functionality. The smart sensor consists of (i) chemical and process information in the physical twin by smart field devices, by measuring multiple components, and is fully connected in the IIoT 4.0 environment. In addition, (ii) it includes process intelligence in the digital twin, as to being able to generate knowledge from multi-sensor and multi-dimensional data. The cyber-physical system (CPS) combines both elements mentioned above and allows the smart sensor to be self-calibrating and self-optimizing. It maintains its operation autonomously. Furthermore, it allows—as central PAT enabler—a flexible but also target-oriented predictive control strategy and efficient process development and can compensate variations of the process and raw material attributes. Future cyber-physical production systems—like smart sensors—consist of the fusion of two main pillars, the physical and the digital twins. We discuss the individual elements of both pillars, such as connectivity, and chemical analytics on the one hand as well as hybrid models and knowledge workflows on the other. Finally, we discuss its integration needs in a CPS in order to allow is versatile deployment in efficient process development and advanced optimum predictive process control. KW - Smart sensors KW - Industry 4.0 KW - Digital twins KW - Process intelligence KW - Process analytical technology KW - Physical twin KW - Cyber-physical system PY - 2020 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-503980 DO - https://doi.org/10.1007/s00216-020-02421-1 SN - 1618-2642 VL - 412 IS - 9 SP - 2037 EP - 2045 PB - Springer CY - Berlin Heidelberg AN - OPUS4-50398 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Eisen, K A1 - Eifert, T A1 - Herwig, C A1 - Maiwald, Michael T1 - Current and future requirements to industrial analytical infrastructure—part 1: process analytical laboratories N2 - The competitiveness of the chemical and pharmaceutical industry is based on ensuring the required product quality while making optimum use of plants, raw materials, and energy. In this context, effective process control using reliable chemical process analytics secures global competitiveness. The setup of those control strategies often originate in process development but need to be transferable along the whole product life cycle. In this series of two contributions, we want to present a combined view on the future of PAT (process analytical technology), which is projected in smart labs (part 1) and smart sensors (part 2). In laboratories and pilot plants, offline chemical analytical methods are frequently used, where inline methods are also used in production. Here, a transferability from process development to the process in operation would be desirable. This can be obtained by establishing PAT methods for production already during process development or scale-up. However, the current PAT (Bakeev 2005, Org Process Res 19:3–62; Simon et al. 2015, Org Process Res Dev 19:3–62) must become more flexible and smarter. This can be achieved by introducing digitalization-based knowledge management, so that knowledge from product development enables and accelerates the integration of PAT. Conversely, knowledge from the production process will also contribute to product and process development. This contribution describes the future role of the laboratory and develops requirements therefrom. In part 2, we examine the future functionality as well as the ingredients of a smart sensor aiming to eventually fuel full PAT functionality—also within process development or scale-up facilities (Eifert et al. 2020, Anal Bioanal Chem). KW - Smart test laboratories KW - Laboratory 4.0 KW - Sustainable Production KW - Industry 4.0 PY - 2020 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-504020 DO - https://doi.org/10.1007/s00216-020-02420-2 SN - 1618-2642 VL - 412 IS - 9 SP - 2027 EP - 2035 PB - Springer CY - Berlin Heidelberg AN - OPUS4-50402 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -