Powering a sustainable future

As global nations work towards net zero targets, reducing energy consumption in manufacturing is critical. However, the growing use of automation and robotics is increasing energy requirements.

Here Ross Turnbull, Director of Business Development and Product Engineering at Swindon Silicon Systems, explains how custom ASICs are key to improving energy efficiency in industrial applications.

As manufacturing becomes increasingly digital, smart factories rely on interconnected systems powered by robotics, sensors and AI-driven machinery. These technologies enable continuous production optimisation, reducing downtime and improving efficiency.

While automation typically improves energy efficiency per unit of production, the greater computational and operational demands of smarter systems can lead to a larger overall energy footprint.

Integrated circuits (ICs) are essential for key functions in smart factories, including motor control, sensor data processing and machine communication. While individual ICs may not consume large amounts of power, optimising them for low power consumption and high performance is critical for minimising energy waste.

As industries scale and adopt more intelligent automation, balancing computational power with energy efficiency in ICs is crucial. Poorly optimised ICs can lead to excessive energy consumption, increased cooling requirements and reduced system longevity, ultimately raising operational costs and environmental impact.

The challenges of traditional ICs

Off-the-shelf, general-purpose ICs are commonly used in industrial applications due to their cost-effectiveness and availability. However, they often prove inefficient in energy-sensitive industrial environments because they are designed for broad use rather than being optimised for specific tasks.

A standard IC is not fine-tuned for critical industrial functions such as sensing, performing complex calculations, controlling or digital signal processing (DSP). As a result, it often executes more operations than necessary, leading to inefficiencies.

For instance, when processing sensor data or performing DSP tasks like filtering or transformation, a standard IC may take longer to complete computations because it lacks specific optimisation. The prolonged execution time keeps the chip active for extended periods, drawing more power than a custom solution.

Moreover, standard ICs often include additional features and processing capabilities that are irrelevant to the specific application. In sensing applications, for example, a standard IC may execute unnecessary communication protocols or auxiliary data processing that do not directly contribute to the primary function. These additional operations increase power consumption and reduce overall system efficiency.

As automation scales up, these inefficiencies compound, leading to greater energy waste and higher operational costs. This underscores the need for application-specific solutions that optimise both performance and energy consumption.

Custom ASICs: a smarter solution

Custom-designed Application Specific Integrated Circuits (ASICs) provide an efficient solution by optimising energy use in specific industrial applications.

Unlike general-purpose ICs, ASICs are engineered for distinct tasks, eliminating unnecessary circuitry and minimising power draw. They can be precisely tuned to effectively enhance both performance and energy consumption by meeting targeted requirements.

For instance, in robotic systems, ASICs can be tailored to refine motor control by optimising pulse-width modulation (PWM) signals, ensuring motors operate efficiently with minimal energy loss. This customisation ensures that each motor performs at peak efficiency, improving overall system performance and reducing waste.

In automated production lines, ASICs with adaptive power management can adjust power distribution based on real-time demands. This ensures machinery operates efficiently by reducing energy consumption during lower power tasks while maintaining performance, preventing the system from running at full capacity when it’s not required.

The efficiency of integration

One of the most significant advantages of custom ASICs is their ability to integrate multiple functions onto a single chip, streamlining design and boosting overall system efficiency.

Traditional industrial systems rely on several discrete ICs for tasks such as signal processing, power management and motor control. This approach, however, increases power consumption, heat generation, and overall complexity.

ASICs consolidate these functions, reducing energy losses from inter-chip communication and minimising the number of required components. Modern mixed-signal ASICs take this integration further by combining both analogue and digital circuitry on a single chip.

They incorporate analogue front-end circuits – such as amplifiers, filters and analogue-to-digital (ADC) and digital-to-analogue (DAC) converters – with digital processing cores to capture, convert and process sensor data in real time. This integration not only eliminates the need for extra power-hungry components but also enhances signal fidelity, reduces latency and mitigates inter-chip noise.

Reducing waste

By consolidating multiple functions onto a single chip, they minimise the number of components required for assembly. In addition, the durability of ASICs means fewer component failures and replacements, which further limits electronic waste over time.

These efficiency gains offer both environmental and economic benefits. By reducing the number of components and materials needed, custom ASICs decrease waste generation, lower production costs and support more sustainable manufacturing practices.

Swindon Silicon Systems partners with manufacturers throughout the design process –starting from initial specifications to wafer production, packaging and testing. This collaboration ensures that each ASIC is optimised for energy efficiency, functionality and long-term reliability, helping manufacturers meet the operational demands of diverse industrial applications.

Integrating custom ASICs into industrial systems is not just about achieving better energy efficiency; it’s about embracing a future where sustainability and performance go hand in hand. ASICs will play a key role in balancing high-performance automation with energy efficiency as industries evolve, paving the way for smarter, greener industrial solutions.