Cost Efficiency and Effectiveness: Insights from TH Köln
A study by TH Köln clearly demonstrates that Ethernet-APL is not only technologically superior to traditional 4...20 mA point-to-point wiring systems, but also economically viable. The analysis shows that APL installations are significantly less expensive than conventional trunk cable solutions. Compared to Remote I/O systems, the costs are nearly equal, but Ethernet-APL brings additional benefits through easier planning, faster commissioning, and reduced maintenance expenses.
The greatest savings can be realized during the planning phase: Detailed pre-planning is no longer necessary, as an as-built model can be created online during operation. This saves time, prevents planning errors, and simplifies later modifications. Additionally, Ethernet-APL enables reverse polarity protection and digital loop checks, significantly accelerating commissioning processes.
Market Availability: Devices and Systems Are Gaining Momentum
According to a manufacturer survey conducted by atp magazin, APL-capable control systems and initial field switches are already available today. Asset management systems for Ethernet-APL are being introduced to the market. In the field device and positioner segments, a range of compatible devices is already on the market. By 2026, the product portfolio is expected to expand significantly – covering nearly all measurement principles via Ethernet-APL.
This development shows that the industry has recognized the potential of Ethernet-APL and is actively investing in compatible solutions. The foundation for a fully digital ecosystem in the process industry is now being established.
Proven Scalability: Large-Scale Testing with Over 200 Field Devices
A scalability test initiated by BASF, in cooperation with several manufacturers, confirms the practical applicability of Ethernet-APL. In a realistic testing environment, more than 200 field devices were operated using PROFINET over Ethernet-APL in a ring topology. Field switches from various manufacturers, including R. STAHL, Pepperl+Fuchs, and Phoenix Contact, were used in the setup.
The results are clear: The networks operated stably and reliably, even under high load conditions. Particularly noteworthy was the short redundancy switching time. The test also demonstrated full interoperability between devices from different vendors – a strong confirmation of APL’s open standard approach.
Another test highlight: Integration into existing control systems worked seamlessly. For example, an Emerson DeltaV DCS with system redundancy (S2) support was used, along with the AMS Device Manager. Integration into asset management platforms such as Endress+Hauser's Netilion also presented no issues.
Field-Tested Technology: R. STAHL’s Field Switch in Action
The new Ethernet-APL Field Switch from R. STAHL was tested under real-world conditions – complete with ATEX and IECEx certification for use in Zone 1 and Zone 2 environments. The outcome: excellent PROFINET compatibility, high stability, and full suitability for hazardous area operation.
In a ring structure with 15 switches and over 200 field devices, the system demonstrated its scalability and robustness. Thanks to the two-wire power supply with intrinsic safety, cabling efforts remain minimal. This makes the Field Switch a key component for enabling seamless Ethernet communication all the way to the field level – even in explosive environments.
Growing Adoption: Projects with Over 1,000 Measurement Points Planned
Several NAMUR members are planning their first Ethernet-APL projects with more than 1,000 measurement points by 2026 – a strong signal for the broad rollout of the technology. At the same time, NAMUR and ZVEI are working on a whitepaper describing how Ethernet-APL can be gradually integrated into existing (brownfield) plants. The goal is a flexible, modular I/O layer, enabling a smooth and low-risk transition from legacy systems to future-ready technologies.
Technological Advantages: More Than Just Faster Communication
Ethernet-APL does more than just improve data transmission. It brings tangible benefits across the entire plant lifecycle:
Simplified Engineering: No need for extensive pre-planning of the physical infrastructure. Modifications and expansions can be implemented easily.
Faster Commissioning: The digital nature of the technology eliminates many manual testing steps. Wiring errors are avoided by design.
Transparent Diagnostics: Through FDI and the NAMUR Open Architecture (NOA) model, standardized diagnostic data can be provided via the PA-DIM model – a critical enabler for predictive maintenance and AI-driven condition monitoring.
Scalable Data Analysis: In large-scale or global deployments, a data lake can serve as a central hub for storing and analyzing diagnostic data.
Conclusion: Ethernet-APL Is Ready – Are You?
Experience to date with Ethernet-APL presents a clear picture: The technology is market-ready, powerful, and economically advantageous. The first large-scale projects have begun, extensive tests have been completed, and a wide range of devices and systems are already available or on the verge of market launch.
Ethernet-APL provides the process industry with a tool that extends digitalization deep into the plant. The manufacturers who invested early in this technology have proven their foresight – and now users have the opportunity to adopt a mature and reliable standard.
It is now up to planners, system integrators, and operators to take the next step. The advantages of Ethernet-APL – from reduced capital expenditure and faster commissioning to comprehensive data availability – are not theoretical. They have been demonstrated and verified in real-world practice.
By adopting Ethernet-APL today, you lay the groundwork for modern, future-proof industrial automation – and take your facility one significant step closer to complete digital transformation.
