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In a recent ARC Advisory Group podcast, Craig Resnick, Vice President at ARC Advisory Group, sat down with Manishi Tiwari, Senior Director of EcoStruxure Power & Process Programs at Schneider Electric, to explore why this convergence is accelerating and how it is reshaping industrial operations worldwide.
From Parallel Worlds to a Unified Industrial System
Historically, power systems and process automation systems were designed, engineered, and operated as separate domains. Electrical systems focused on reliability and protection, while process control systems focused on throughput, quality, and safety. This separation made sense in an era of limited connectivity and static energy supply models.
Today, that model is breaking down. Digitalization, Industrial IoT, software defined automation, and advanced analytics have made it possible—and necessary—for power and process systems to operate as a single, integrated environment. As discussed in the podcast, manufacturers can no longer make optimal production decisions without understanding energy availability, pricing, and grid constraints in real time. Likewise, power systems can no longer be managed effectively without visibility into process demand.
Podcast
Mega Trends Driving Convergence
During the discussion, several powerful macro trends emerged as key drivers of power and process convergence. One of the most significant is the global push toward sustainability and decarbonization. Energy production and consumption account for the majority of global carbon emissions, placing increasing pressure on industrial companies to reduce their environmental footprint.
Electrification of industrial processes is central to this shift. While only a small portion of industrial heat is electrified today, a much larger share could be electrified using existing technologies. At the same time, renewable energy sources such as wind and solar are becoming more cost competitive and, in some regions, are already outpacing fossil fuels in power generation. These dynamics are forcing industrial organizations to rethink how energy is sourced, managed, and consumed across their operations.
Another critical trend is the rapid growth in electricity demand, driven not only by population growth and urbanization but also by data centers, AI workloads, and digital infrastructure. As grids face higher loads and increased volatility from renewable generation, resilience and flexibility are becoming as important as efficiency. This reality makes integrated power and process visibility essential.
Electrification Changes the Nature of Operations
One of the most important insights from the conversation is that electrification fundamentally changes how industrial processes operate. Electricity is no longer just a utility used to run auxiliary equipment; it is increasingly becoming the primary energy source for core processes such as heating, compression, and material transformation.
This shift introduces new operational challenges. Renewable energy sources are variable by nature, energy pricing can fluctuate dramatically, and grid constraints can impact production. Without tight integration between energy management systems and process control systems, operators lack the information needed to make informed decisions about when to produce, when to consume, and when to adjust production schedules.
The Role of Digital Twins and Lifecycle Integration
A recurring theme throughout the podcast was the importance of digital twins and lifecycle integration. By creating digital models of both electrical and process systems early in the design phase, organizations can simulate different operating scenarios before making costly capital investments. These models help answer critical questions, such as how changes in production capacity affect electrical infrastructure or how electrified equipment will behave under varying load conditions.
Beyond design, digital twins also support operations by enabling operator training, scenario testing, and faster troubleshooting. When power and process data are unified within a single operational environment, operators gain a “single version of the truth,” reducing downtime and improving decision making—especially in an era of workforce turnover and skills shortages.
Why Integration Is Now a Competitive Necessity
As Craig Resnick emphasized during the discussion, manufacturers operating in a global, AI driven economy cannot remain competitive without aligning power and process decisions. Unplanned downtime, inefficient energy use, and poor coordination between electrical and operational teams directly impact profitability, safety, and sustainability performance.
The podcast highlights how integrated architectures—such as Schneider Electric’s EcoStruxure Power & Process approach—are designed to break down traditional silos while allowing power and process systems to coexist and share information seamlessly. This integration supports better lifecycle outcomes, from early stage design decisions through long term operations and optimization.
A Mandate, Not an Option
The key takeaway from the conversation is clear: sustainability, efficiency, and resilience are no longer optional goals. They are expectations placed on industrial organizations by customers, investors, regulators, and society at large. Achieving these goals requires a fundamental rethinking of how power and process systems are designed and operated together.
As industrial electrification accelerates and energy systems grow more complex, convergence is no longer a technology experiment—it is a strategic imperative. Organizations that embrace integrated power and process architectures will be better positioned to navigate uncertainty, improve performance, and lead in the next era of industrial transformation.