According to the International Energy Agency, industrial energy consumption makes up nearly one-third of global energy demand. 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 ASIC design and supply specialist Swindon Silicon Systems, explains how 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. 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.
The challenges of traditional ICs
Integrated circuits (ICs) are essential for key functions in smart factories, including motor control, sensor data processing and machine communication.
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. This is because 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, introducing inefficiencies.
For example, 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. 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 and lowering operational costs.
A smarter solution
Application Specific Integrated Circuits (ASICs) provide a more efficient solution. Unlike general-purpose ICs, ASICs are engineered for distinct tasks, eliminating unnecessary circuitry and minimising power draw.
For instance, in robotic systems, ASICs can be tailored to refine motor control by optimising pulse-width modulation (PWM) signals, ensuring motors operate at peak efficiency, improving overall system performance and reducing waste.
Furthermore, traditional industrial systems rely on several discrete ICs for signal processing, power management and motor control. However, this increases power consumption, heat generation and overall system complexity. In comparison, 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. These chips combine 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 not only eliminates the need for extra power-hungry components but also enhances signal fidelity, reduces latency and mitigates inter-chip noise.
This consolidation has secondary environmental and economic benefits. By reducing the number of components and materials needed, 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.
