Automation for a world in motion. From one hundred successful years to a promising future. Highlights Anniversary Edition 2025
Automation for a world in motion. From battery cell to acceleration. Festo products and solutions are setting the stage for flexible, intelligent and efficient automated manufacturing processes of nearly everything that moves us – cars, planes, trains, e-scooters. I 100.festo.com
“By being open, curious, enthusiastic, and willing to learn. That is at the heart of our innovation, of being able to think beyond boundaries and daring to try something new”. Thomas Böck, Chairman of the Management Board Dear Reader, This will be a unique year, and we are delighted to be marking this occasion as Festo turns 100! One hundred years of success and innovation – that’s what Festo stands for. Festo keeps the world moving with automation as well as technical basic and further training. With this anniversary edition of the “Highlights” brochure, we would like to reflect on the future by exploring topics that move you and us – and thank you. Thank you for shaping the industry of today – and above all of tomorrow – with us! I am looking forward to a year full of highlights and especially to many personal anniversary moments with you – our customers, our partners, and all innovation enthusiasts. “Automation for a world in motion” – Our customers in factory and process automation have many different requirements. Our aim is to meet these requirements as efficiently and sustainably as possible, regardless of the technology used. Festo is the first port of call for a broad and networked spectrum of automation technology, ranging from products and solutions for pneumatic and electric automation to digitalization and AI, rounded off by expertise in technical basic and further training. In this issue, we show you exciting customer projects from various industries that underline our broad expertise and our partnership-based cooperation, not only in terms of technology, but in terms of training too. We will also be exploring the sustainable transformation of industrial production with trendsetting solutions by focusing on topics such as hydrogen, biotech automation, and the circular economy. A lot of knowledge from Festo as well as from renowned industry experts is awaiting you. I hope you will be inspired by the ideas and will find plenty of food for thought! Thomas Böck Chairman of the Management Board, Festo
In April 1925 Albert Fezer and Gottlieb Stoll founded “Fezer & Stoll”, focused on to the manufacture of woodworking machines. The brand name Festo is a combination of the surnames of the two founders and has stood for innovation ever since. After a few years, Gottlieb Stoll took over sole responsibility. His way of thinking and acting was shaped by wanting to make work easier for people. The first company headquarters in Ulmer Straße in Esslingen am Neckar (see picture below) was built in 1939. It was home to modern production and office spaces. The foundation stone for further development had been laid and a place where ideas could be created had been opened. In the mid-1950s, the focus shifted to industrial automation when Festo set started developing pneumatic products and thus set new standards in automation. Festo grew and went global. The first national company was founded in Italy in 1956, followed by Switzerland, France, and Austria. The current headquarters were built back in 1962, at the first dedicated site for the Festo Pneumatics division in Esslingen-Berkheim; Administration and Production were now centralized. Six years later, Festo opened a production site in Rohrbach, Saarland; today, this site is its largest production and logistics center in the world. Based on the firm conviction that innovative strength and competitiveness go hand in hand with learning and knowledge, the company set up Festo Didactic in the 1960s, with the specific aim of developing training courses for apprentices, employees and customers. It quickly became the leading provider of technical training and further education. „Festo – one mission, many hands.“ Gottlieb Stoll with his wife Berta In motion for 100 years. More impressions and information about our successful company history: > www.festo.com/history
Automation for a world in motion. Highlights 2025 Festo 100 years 4 – 5 The first pneumatics catalog from 1956 comprised 166 items. Today’s portfolio has about 33,000 catalog products in several hundred thousand variants. In 1950, Kurt Stoll, the eldest son of Gottlieb and Berta Stoll, found out about pneumatics at a trade fair in Chicago and recognized its potential for automation. With his extraordinary, inventive spirit, he developed this topic further at his father’s company. Kurt Stoll made a significant contribution to Festo becoming a pioneering solution provider in automation technology. Wilfried Stoll, the second son of Berta and Gottlieb Stoll, pushed ahead with the international positioning and the founding of new Festo companies to strengthen the brand. He is pictured here during a trip to Southeast Asia in Singapore in 1973 in front of a Festo car. The exhibition stand in 1967 at the Royal Exhibition Building in Melbourne, Australia. Right from the early days, Festo has been present at national and international trade fairs. Festo has been listed as an exhibitor at the Hannover Messe since 1949 and continues to demonstrate its innovative strength at the world’s largest industrial trade fair. Development of the first pneumatic products from 1955. The picture shows the double- acting cylinder type DV.
A 100-year success story – This is only possible when innovative customers come together with a highly competent sales team. We would like to thank our customers around the world this year, for their trust, great inspiration, and a shared view of the future! Frank Notz, Member of the Management Board Sales 2025 will be a year of innovation – of products, functionalities, methods, and the customer interface. Dr. Ansgar Kriwet, Member of the Management Board Research and Development Our success is based on our more than 20,000 employees worldwide. Our experts will continue to have their fingers on the pulse in the future because lifelong learning is part of Festo DNA! Sebastian Beck, Member of the Management Board Finance and Human Resources I am delighted to celebrate this special anniversary at our global production and logistics locations. Because we are active globally in the sense of “local for local”, close to our customers. Dr. Jaroslav Patka, Member of the Management Board Operations This year is all about “the future”. Electric automation, digitalization, and artificial intelligence will play a central role. Gerhard Borho, Member of the Management Board Information Technology and Digitalization
1 2 3 5 4 Highlights 2025 Table of contents 6 – 7 Contents Sustainability 22 > World of Motion 10 Electric automation Decentralized automation Automation with VTUX Digitalization Lifelong learning > BioTech Automation 58 > Festo Incredible Machine 60 > Imprint 62 Reducing CO2 emissions for climate protection | Festo Energy Saving Services | Real-life application: Compressed air energy efficiency audit Hydrogen is ... | Automation solution for green hydrogen production | Real-life application: H2 trailer control system with valve terminal solution Hydrogen 30 Microfluidics: Focus on miniaturization – Interview with Prof. Dr. Roland Zengerle | Smart solutions for laboratory equipment and medical devices | Real-life application: Fast antibiotic diagnostics Life Sciences 38 From Silicon Saxony to Silicon Valley – Interview with Frank Bösenberg and Ajit Manocha | N2 purge systems reduce nitrogen consumption Electromobility 46 Semicon 52 Partner in battery production | Automation in the battery life cycle > Real-life application: Inspecting battery cells and disassembling battery packs
Innovation always finds a way Amidst the majestic backdrop of the Andes, where the air is thin and the challenges are great, a lorry with a trailer – the legendary Expotainer M1 from Festo – is on the move. Developed in 1974 as a mobile trade fair, with 16 static and dynamic displays, air conditioning, a coffee machine, film screenings and the latest product innovations on board, its successful journey was just beginning. And the driver’s travels were always characterized by adventure and ingenuity. Take, for example, the customer tour in South America in the 1980s. The only route from Argentina to Chile leads over a 4,000-meter-high pass. After successfully crossing it, the Expotainer had to make its ways through a tunnel, which had a height restriction for vehicles of max. 3.80 meters. But the Expotainer is 3.95 meters high. A detour would mean an extra 3,000 kilometers and two to three weeks of lost time. What to do? The driver, who was driving one of the first trucks with air suspension, had an idea: he unloaded the trailers, emptied the system, transported the containers through the tunnel one by one, refilled the truck with air, and drove on. This is how many an Expotainer trip turned into a special story that not only showcased the range of services offered by Festo, but also demonstrated the passion and commitment of Festo employees. And this is still true to this day, whether with the modern Expotainer M18 or at a wide variety of trade fairs all over the world. Festo 100 years 8 – 9 Highlights 2025
From pioneering innovations to maximum productivity World of Motion We set the world in motion for our customers. By using innovations to simplify what is complex. Automation from Festo offers the right solutions for everything that ensures sustainable success, maximum productivity, and competitive advantages for our customers, from pneumatics and controlled pneumatics to electric automation and digitalization using AI. Compatible and with seamless connectivity. Our broad expertise allows us to offer you technology-neutral advice, thus opening the door to smart innovations and maximum CO2 savings. And training is just as important as technology. From maximum flexibility to highest precision > Electric automation from Festo for speed and efficiency with seamless connectivity From mechanical systems and controllers to the right cloud application: Thanks to having one of the most extensive portfolios on the market, we can implement almost any movement requirement for our customers using electric automation. Seamless connectivity gua- rantees perfect interaction between all technologies. From comprehensive expertise to lifelong learning > Festo Didactic for learning solutions and developing technical skills As the global market leader in technical basic and further training, we create real added value for our customers on their journey to industrial transformation – and thus the basis for productivity, innovation, and sustainable growth. We systematically pass on our knowledge to the experts of tomorrow. Everything is from a single source, from simple software solutions and individual learning packages to digital learning platforms and comprehensive training centers.
World of Motion 10 – 11 From pure power to smart control > Pneumatics from Festo for reliable and innovative automation solutions in all industries Pneumatics often offers the simplest and most efficient solution. Regardless of the challenge, customers benefit from pneumatic solutions that are based on application knowledge gained over a hundred years of automation experience. Our latest innovation, controlled pneumatics, provides intelligent solutions for more complex tasks. Together with comprehensive design software, digitized pneumatics opens up new possibilities, from precise positioning to fast and flexible control. From real-time tracking to looking into the future > Digitalization from Festo for monitoring and digital tools to AI solutions Festo is one of the pioneers of digitalization and a founding member of the Industry 4.0 platform. Based on our expertise in mechatronics, automation, and AI, we generate real added value. As a partner in industrial automation, we offer individual, comprehensive solutions and support our customers in increasing overall system efficiency with the right hardware and suitable software tools, from design to commissioning, as well as perfect AI apps. “Seamless automation allows us to combine the best of different technologies.” Frank Notz, Member of the Management Board Sales Together we move the world. Welcome to the World of Motion: > www.festo.com/worldofmotion Highlights 2025
Sustainable and efficient packaging Electric Automation Real-life application Perfectly shaped packaging: Stepper motor EMMS-ST on the hood forming module. “The stepper motors reduce the energy consumption of the entire machine.” Wolfgang Konrad, Vice President Marketing & Communication, IWK With the new blister packaging machine from IWK, sustainability is not just lip service. Thanks to the use of recyclable packaging material, its low energy consumption, high speed and ergonomic design, the CABLIblue 870 proves to be a real trendsetter. And with electric automation technology from Festo sustainability and efficiency are significantly increased in this application. IWK Verpackungstechnik GmbH, based in Stutensee near Karlsruhe, Germany, is part of the ATS Group and has more than 7,500 employees at 65 international production sites. It is one of the world’s leading manufacturers of packaging machines, focusing on tube fillers and cartoning systems. With the CABLIblue 870 card-to-card blister system, the company supports its customers on their journey towards a circular economy. The high volumes of sturdy packaging it processes are all made from recyclable cardboard, completely without plastic, and destined for medical technology, pharmaceuticals, cosmetics, DIY articles, and nonfood. Faster with stepper motors When it comes to efficiency, no competitor can beat CABLIblue 870. With a packaging output of 22 cycles per minute, it is 10% faster than the industry average. The machine also achieves this output by consistently using stepper motors EMMS-ST from Festo, which enable overlapping movements.
World of Motion 12 – 13 You can find more information at: > www.festo.com/ea > www.festo.com/catalogue/emmt-st > www.festo.com/ovem > www.festo.com/egc > www.festo.com/elcc > www.festo.com/engineeringtools The stepper motors not only reduce the noise level to below 72 dbA, they also lower the energy consumption of the entire machine. They thus guarantee a greater energy efficiency and reduce the carbon footprint. The vacuum generators OVEM from Festo also contribute to greater efficiency as they integrate an air-saving and monitoring function for the complete vacuum system in order to reduce downtimes (condition monitoring). The vacuum grippers for ejecting the finished blister packs are part of a handling system equipped with electric axes ECC and ELGC from Festo. The magazines for the packaging materials are easily accessible and can be refilled quickly during operation. Here, too, the stepper motors EMMS-ST from Festo provide support as the magazine in the gripping and loading area is moved towards the machine operator for filling. This improves ergonomics and relieves the strain on machine operators. International cooperation in Thailand “A large part of the CABLIblue 870 was developed and assembled in our factory in Thailand. What was impressive about the cooperation with Festo was the uncomplicated procurement of the necessary parts,” explains Wolfgang Konrad, Vice President Marketing & Communication at IWK. “The digital engineering tools were just as readily available for use for our in Thailand as they were in Germany and contact with the Festo project engineers in Thailand went smoothly,” says Konrad. Even if a Festo component was not immediately available in Thailand, all it took was a phone call and the component was ready for delivery in Thailand in no time. Konrad compares the cooperation with Festo with the relationship with IWK customers, the major brand manufacturers: “Brand manufacturers involve us early on in the development of packaging ideas so that we can work together on designing machine-compatible packaging. Such a basis of trust also characterizes our relationship with our development partner Festo.” A handling system with electric axes EGC and ELCC ensures the finished blister packs are reliably transported. Stepper motors on the cover card magazine shortly before sealing. Highlights 2025 > www.iwk.de
> www.prolineautomation.com Real-life application Innovative window production in Canada Decentralized Automation “Decentralized automation with CPX-AP-I simplifies installation and assembly” Vinode Ramnauth, President and CEO of Pro-Line Complex things made simple: Automation solutions from Pro-Line for window and door production, optimized with innovative Festo technology. Festo was on site with its video team: > www.festo.com/proline-video A machine builder from Ontario is countering the shortage of skilled workers with new, decentralized automation solutions from Festo. Modern machines for the flexible production of windows are equipped with innovative technology to save time and effort in design, construction, and commissioning. Maintenance, fault detection and troubleshooting are also made easier and cycle times are shortened. For Pro-Line, one of Canada’s leading OEMs of CNC and largescale manufacturing systems in window and door production, expertise and automation are equally important. The company uses innovative automation solutions to compensate for the nationwide shortage of qualified workers for sawing, drilling, and joining PVC and aluminum. A simplified machine design combined with easier maintenance requires fewer skilled workers. Innovation partner Festo “We want to take our machines to the next level of performance and efficiency, and Festo offers us the opportunity to do so. All our engineering work was developed together with Festo,” says Vinode Ramnauth, President and CEO of Pro-Line. Decentralized automation with the remote I/O system CPX-AP-I is used in the latest window production system. The electronic proximity switch SDBT-MSX with automatic teach-in saves valuable time when building the nearly 20-meter-long machine – as much as two hours without the need for fine-tuning and readjustment during commissioning. It has a detection range of 20 mm and is easy and safe to install, especially when mounting is more difficult. “The innovative strength that Festo constantly demonstrates with new technologies enables us to go further,” explains Ramnauth. Efficient I/O networking The new remote I/O system allows powerful input/output modules and existing valve manifold (terminal) interfaces to be integrated into the most important host systems. End-to-end connectivity and extended diagnostic options increase machine availability and productivity. In addition, integrating it into different control systems with PROFINET, EtherCAT, Ethernet/IP or ModbusTCP is really easy. The Festo remote I/O system CPX-AP-I was initially tested on a parallel welding machine for plastic profile parts used in the manufacture of window and patio door frames. And with great success.
World of Motion 14 – 15 Highlights 2025 > www.festo.com/cpx-api > www.festo.com/catalogue/sdbt Only five hours instead of 40 The advantages of the decentralized automation solution are its short, energy-saving tubing and low cabling requirements. “While an electrician normally spends about 40 hours wiring one of our machines, they only need around five hours with a decentralized I/O design,” says Ramnauth. The decentralized system also reduces the training requirements for employees and thus compensates for the shortage of skilled workers in the long term. Key components such as the valve terminal VTUG and the elec- tronic proximity switches SDBT-MSX are connected to the PLC via the CPX-AP-I system and do not need to be connected directly to the bus system. Valve terminals placed at the point of operation By switching to decentralized automation solutions, valuable space could be saved and the workload was reduced too. “We can now position valve terminals and I/O modules directly at the point of operation and don’t have to concentrate them in a central place. Until now, the centralized design usually necessitated larger dimensions,” says the Pro-Line CEO. “It is a great advantage for us that we can now install the valve terminal and the I/O modules exactly where we need them. This means we need fewer tubing and electrical cables and achieve shorter cycle times.” Anniversary in Canada Festo Canada is celebrating 50 years of success! Since its founding, the company based in Ontario has established itself as the market leader in pneumatics in Canada, continuously supporting the local industry. Over the years, Festo introduced local cylinder production, which evolved to meet changing needs, as well as a Customer Interaction Center to deliver dedicated support and tailored solutions. Recently, Festo Canada launched the Certified System Integrator Program. This program connects end users with skilled partners for automation projects. As Festo Canada approaches its 50th anniversary in 2025, it celebrates a legacy of innovation and market leadership. Decentralized automation with the Festo remote I/O system CPX-AP-I simplifies installation and assembly and saves valuable time. Festo modules are integrated directly at the point of operation thanks to excellent connectivity, which also reduces cabling costs.
Real-life application Fast processing of roses in the Netherlands Automation with VTUX In the Netherlands, the land of cut and potted flowers, the machine building experts at Aventec are setting new standards. Speed and precision in processing rose cuttings have been significantly increased with modern, decentralized Festo automation technology. When looking at potted roses, few people think of highly automated processes. But with quantities in the millions, short planting times are a must. The Dutch company Aventec, founded by John van de Ven, opens the door to extremely fast yet sensitive automation in horticulture. With a new design that was originally planned as an automation upgrade at a breeding company, Van de Ven was able to increase the output of a complete machine with four cutting stations to up to 5,200 cuttings per hour. The system was equipped with modern servo technology, controlled by the Festo automation platform CPX-E. The perfect pattern The Aventec system trims the rose cuttings to size and plants them in pots in a matter of seconds. At the start of the line, the rose twigs are first hooked into a transport system by hand; all subsequent steps are fully automated. Once in the processing cells, the cuttings are positioned in front of an image processing system and rotated 180 degrees to create a 3D scan. The machine software then determines the optimum cutting pattern for the cultivated plants; this is carried out extremely quickly and precisely by a multi-axis robot. Finally, the robot inserts the cuttings into pots filled with soil after which the potted roses begin their journey into the greenhouse. To find out how the turning and cutting processes could be realized with components from Festo, Van de Ven and his team sent rose twigs and their holders to the Festo development center in Delft. A week later, they received a video from the Festo team with the results. Fully automated filigree work: The new machine from Aventec cuts and plants up to 5,200 rose cuttings per hour using Festo components.
Highlights 2025 World of Motion 16 – 17 > www.aventec.nl Advantage of decentralized control A key component for the high speed of the machine is the compact valve terminal VTUX. It allows both a decentralized and a centralized machine design. Van de Ven opted for the decentralized design variant for the new machine. “With VTUX, I can position the connection points closer to the sensors,” explains Van de Ven. “We only need one supply connection for air, electricity, and communication to the terminal. And where we used to need two control cabinets to accommodate everything, now one cabinet is enough. Thanks to the decentralized control system, everything can be operated independently.” Reliable and fast diagnostics The Festo automation platform CPX-AP-A makes a valuable contribution to fast and error-free IO control between components. Extended diagnostic functions enable fast response times in the event of a malfunction. For example, a cable break in one of the sensors on the machine can be reliably localized in no time at all. To do this, all tags are read in and assigned in the VTUX. For each rose cutting module, there is one terminal in the upper and one in the lower section of the machine, as well as a valve terminal VTUX on the main unit – a total of nine per machine. The special feature of the valve terminal VTUX: It is suitable for both decentralized and centralized machine installation. At Aventec, they opted for decentralized control. > www.festo.com/vtux > www.festo.com/cpx-e > www.festo.com/cpx-ap-a “Where we used to need two control cabinets, now one is enough.” John van de Ven, Managing Director Aventec
Real-life application Festo AX Smartenance optimizes maintenance management Digitalization in Tunnel Construction Festo was on site with its video team: > www.festo.com/herrenknecht-video
World of Motion 18 – 19 Highlights 2025 > www.herrenknecht.com > www.festo.com/ax With lengths of up to 150 meters and diameters of up to 17 meters, Herrenknecht tunnel boring machines are true giants. They are used in many infrastructure projects all over the world to excavate tunnels quickly and efficiently. At Europe’s largest infrastructure construction site in London, a rail link, High Speed Two (HS2), is being constructed between the north of England and London for trains traveling at up to 360 km/h. Two Herrenknecht tunneling machines are being used, whose reliability is based, among other things, on the digital maintenance manager AX Smartenance from Festo. The Festo software is integrated into the Herrenknecht.Connected digital system. Focus on maintenance To ensure complex systems such as a tunneling machine can function without interruption, having a deep insight into the internal condition of the machines and seamless maintenance are crucial. In the past, necessary maintenance work often resulted in excessively long and expensive downtimes, while documentation on paper was slow, laborious, and complex. With the digital customer portal Herrenknecht.Connected, Herrenknecht customers receive insights into and data from almost all systems on the construction site, from a tunneling machine in operation to wastewater treatment. The family-owned company also wanted to integrate a modern and user-friendly maintenance management system into this platform. Everything at a glance While researching the market, the IT specialists at Herrenknecht came across AX Smartenance from Festo. The maintenance software, also known as CMMS (Computerized Maintenance Management System), allows production managers and plant operators to carry out digital maintenance and servicing. Maintenance tasks and plans can be flexibly created, duplicated, and then evaluated, while intelligent user management improves fast teamwork and boosts the efficiency of maintenance management. Transparent monitoring, intuitive operation: Festo AX Smartenance, the digital maintenance management solution, in use on the HS2 tunnel construction project in London. Integrated into Herrenknecht’s customer portal, the CMMS AX Smartenance is responsible for the maintenance management of tunnel boring machines and all other maintenance-relevant machines and systems on a large construction site. It provides automated analysis functions, clear dashboards, and detailed evaluations of sensor data. This, in turn, reduces downtimes, minimizes the time required for maintenance and thus significantly reduces costs, all while increasing efficiency. Maintenance staff and mechanics working on the machine also benefit from AX Smartenance. This is because the teams on site can now process, report and track routine tasks and incidents directly via the CMMS software. All maintenance-relevant documents such as circuit diagrams and drawings are available in one central location. As a result, the work of the maintenance teams becomes much easier and productivity increases.
Megatrends such as digitalization and the challenges of climate change are influencing many areas of life, including technical education. This helps to actively shape future changes and drive innovation. At Festo, lifelong learning is firmly embedded in our corporate culture. As early as 1965, an independent division was established, tasked with the worldwide sales of learning systems and the organization of courses. Today, Festo Didactic is a global leader in technical basic and further training. Used by customers from vocational colleges, universities, research centers, educational instituties and industrial companies all over the world, technical education becomes a driving force for innovation. The specialists of today and tomorrow are empowered to master the challenges of the future. They make a significant contribution to the competitiveness of companies and to boosting the economy by driving innovation with their new skills and ideas. Well-trained employees will enable industrial companies to react more quickly to market changes and position themselves more successfully globally. Festo Didactic – partner for the development of technical expertise Lifelong Learning “Lifelong learning is the way to meet global challenges with knowledge and innovation.” Dr. Oliver Niese, Member of the Board Festo Didactic Customized training solutions Existing professions are constantly changing and new job profiles are emerging. Festo Didactic grasps new technologies and offers educational institutes customized training solutions and reli- able partnerships. Together, young people are optimally prepared for the world of work and trained to contribute to a sustainable economy. With its comprehensive portfolio, Festo Didactic offers companies and their specialists many innovative solutions for lifelong learning. These are tailored to the training requirements of industry and cover technologies such as factory and process automation, fluid technology, electrical engineering, as well as new topics such as electromobility (see also page 49). Current trends are thus also included in further technical training. > www.festo.com/didactic
Highlights 2025 World of Motion 20 – 21 In focus: Sustainability Green skills are environmentally friendly skills that contribute to sustainable development. These include technologies such as renewable energies (solar, wind and hydropower), energy efficiency, sustainable mobility, and building technology. Festo Didactic promotes green skills as a way of teaching sustainable business practices and supporting the transition to a climatefriendly industry. By training customers, partners, and its own employees in relevant sustainability topics, Festo Didactic helps them to better understand the environmental impacts and make sustainable decisions. The water industry is a prime example of a high-tech sector in which employees require an increasingly broad range of skills. Festo Didactic offers effective learning methods using training systems and simulations that recreate real conditions in the water industry. Virtual experiments with complex water management systems can thus be carried out safely and realistically. > www.festo.com/greenskills Learning through competing The international WorldSkills vocational competitions aim to nurture prospective skilled workers and strengthen cooperation between representatives from education, business, and politics. Festo Didactic has been involved in the world’s largest education trade fair for over three decades, both as a global industry partner and official supplier of competition equipment. In addition to established professions, new job profiles are also showcased as future professions. Festo Didactic was able to help integrate the disciplines of Water Technology, Industry 4.0 (IIoT), and Renewable Energies into the competitions. Digital learning solutions Teaching theoretical knowledge, applying it directly in practice and consolidating it are inseparable parts of technical basic and further training. The targeted combination of digital courses and practical exercises enables learners to remain competitive in highly technological industries. At the heart of the learning solutions is the digital learning portal “Festo Learning Experience” (Festo LX) with a comprehensive learning environment that is tailored to the individual requirements of customers. During their basic and further training, learners can study the theory and practice of a wide range of topics, from factory auto- mation and fluid technology, the Industrial Internet of Things (IIoT) and Industry 4.0 to electrical engineering, process automation, renewable energies, and STEM. For example, Festo LX can provide support with the design of environmental management. Sustainabilityrelated topics such as energy, water and material consumption or CO2 reduction, and compliance with environmental legislation can be integrated into the training, too. Festo LX is already used by over 1700 customers with more than 75,000 active learners and access to over 740 courses. > www.festo.com/lx > www.festo.com/worldskills
1 Sustainability is already firmly integrated in many companies and sectors and forms the basis for responsible industrial development. This responsibility begins on the shop floor and extends along the entire value chain. Automation plays a crucial role in increasing the efficiency of processes and contributes significantly to reducing the carbon footprint of companies. Festo supports its customers with CO2-optimized products, energy efficiency modules, and TÜV-certified Energy Saving Services, such as compressed air energy efficiency audits. They can significantly reduce energy consumption. Sustainability
Highlights 2025 Sustainability 22 – 23
As a family-owned company, Festo stands for clear values, the highest quality, and customer-oriented innovations. This means that Festo as a company needs to make a contribution to sustainable development in the areas of environment, social affairs and governance (ESG). This is how sustainable decisions are made – responsibly and in the long term – for customers, for the company and for future generations. The continuous reduction of the carbon footprint, both for customers and for Festo, is a key focus of sustainable decisions. Festo offers its customers efficient and productive solutions in industrial production. The climate friendly transformation of production along the entire value chain is one of the main tasks for the company. At Festo, the focus is on people. After all, a healthy, motivated and high-performing workforce is a key guarantee of success for us. In order to achieve the Sustainable Development Goals, it is important to set and adhere to binding ethical and governance standards worldwide. The sustainability goals from Festo are bundled into four areas of action. More information on the Areas of action can be found here: > www.festo.com/sustainability > www.festo.com/peopleatfesto Technical education People at Festo Ethics and Governance Climate protection and resource efficiency Our contribution to Social dimension Governance Environment > www.festo.com/sustainableeducation > www.festo.com/ethics-and-governance Sustainability Reducing carbon emissions to combat climate change
Sustainability 24 – 25 Highlights 2025 VTEM ADN-S DSNU-S DRVS DHPC DRRS DGC MSE6-C2M VEAB OVEM SFAM HPPF On the way to carbon neutrality For Festo, climate protection means actively contributing to the reduction of greenhouse gas emissions. Innovative production technologies and recycling strategies reduce the consumption of resources and extend the service life of products. Festo will massively reduce its carbon footprint over the next few years. Since 2024 – two years earlier than planned – the entire Festo Group has been CO2- compensated in Scope 1. Since 2024, the Festo Group has already been carbon-neutral in Scope 2 and 3.8. The plan is to reduce Scope 1 emissions by about 30% by 2030 and to achieve the net zero target by 2040. “By integrating sustainable technologies and processes into our products, we help our customers achieve their own sustainability goals and therefore boost their competitiveness.” Marcus Stemler, Head of Corporate Sustainability, Festo Festo ensures its products are manufactured sustainably and supports its customers on the way to the CO2-neutral factory. With its expertise in pneumatics and electrics, as well as software and AI, Festo can provide technology-neutral advice and maximize CO2 savings through smart innovations. Thanks to a uniquely broad portfolio, Festo offers CO2-optimized products and provides customers with services throughout the entire utilization phase. By using the right technology and optimally sized components, customers can save up to 70% on energy. Product shopping cart for CO2 reduction: You can find the product selection in the Online Shop. ... products with energy-saving function Examples of... ... lighter weight products See page 49
Greater energy efficiency, fewer carbon emissions The Festo Energy Saving Services, certified according to DIN EN ISO 11011, offer a customized service that provides up-to-date information on the condition of compressed air systems and installations. Based on this independent and objective assessment, a detailed overview of the savings potential and valuable recommendations for action are provided so that this potential can be used to the full. More information about the Festo Energy Saving Services can be found here: > www.festo.com/ess The compressed air energy efficiency audit is part of the Festo Energy Saving Services and offers an independent, comprehensive analysis of compressed air systems. The condition of all components, from the compressor to the pneumatic application, is inspected completely objectively. Specific potential savings are then identified, and targeted measures proposed to optimize systems and installations. The result: Lower energy costs, lower carbon emissions, and fewer unplanned machine downtimes for greater production stability. Compressed air energy efficiency audit Benefits: • Independent and comprehensive analysis of the entire compressed air system • Recommendations for action and prioritization of measures to optimize energy efficiency • TÜV-certified in accordance with ISO 11011 • Savings potential of up to 60% for pneumatic systems • Support with DIN EN ISO 50001 compliance • Greater productivity and process reliability The Pneumatics Sustainability Check is an innovative service that is part of the Festo Energy Saving Services. During the check, we systematically inspect the pneumatic components and locate any leaks in your compressed air systems. These leaks are then evaluated in terms of energy loss, costs, and carbon emissions. The check provides a concrete calculation of potential savings, as well as a detailed list of necessary repairs, including the required spare parts. Pneumatics Sustainability Check Benefits: • Transparent information about energy losses caused by leaks • Analysis of potential savings on compressed air, costs, and carbon emissions • Detailed list of necessary repairs, plus recommended spare parts • Clear documentation of all results in the Festo Energy Saving Services Portal • It is also possible to do it yourself. On request, Festo experts will provide training in advance. Sustainability Festo Energy Saving Services
Highlights 2025 Sustainability 26 – 27 Audit in four steps: 1. Analysis of compressed air generation 2. Analysis of compressed air preparation 3. Analysis of compressed air distribution 4. Analysis of pneumatic applications “Only a comprehensive approach guarantees a compressed air system is optimally energy efficient.” * Heiko Fleischhacker, Certified Energy Efficiency Auditor at Festo * On the next page, you can follow Heiko Fleischhacker as he visits a customer. “The portal calculates the savings and classifies the leaks so that you can immediately identify the highest optimization potential.” Jürgen Billep, Certified Energy Efficiency Auditor at Festo The Festo Energy Saving Services Portal provides the necessary transparency for optimizing compressed air systems. Leakage detection results and findings about the inspected pneumatic components are easi- ly and clearly documented. The mobile app enables users to collect data directly at the production system and reliably synchronize it on the portal. With the free trial license, new functions can be tried out. Festo Energy Saving Services Portal
Rising energy costs and environmental regulations make energy efficiency indispensable. Gessner has sustainably increased energy efficiency in its own company thanks to Festo Energy Saving Services. All processes, from the compressor to the pneumatic applications, were analyzed on site by Festo experts and successfully optimized. According to the German Federal Statistical Office, the production of paper, cardboard and goods made from them is one of the five most energy-intensive industries. Gessner, part of the Mativ Group, is the European mar- ket leader in the technical specialty papers and synthetic materials sector. It manufactures filtration products for the automotive industry at its site in Feldkirchen- Westerham, Germany, and is constantly developing new solutions. “It is easy to become blind to existing production processes and operations,” says Armin Niederhuber, responsible for Energy Management at Gessner. “That’s why we brought in the expertise from Festo in the person of Heiko Fleischhacker, to help us see and improve things that we don’t have an eye for ourselves.” The energy efficiency expert and certified auditor at Festo is used to not only taking a close look, but also to determine exactly where energy is not being used efficiently. Efficiency and transparency According to Heiko Fleischhacker, an audit always makes sense if a company wants to obtain an objective assessment and a precise picture of the current condition of its compressed air system. The aim is to identify inefficient areas and opportunities to save energy. During his audit, Heiko Fleischhacker analyzed the entire compressed air system at Gessner and quickly identified shortcoming that, once remedied, led to sustainable energy savings. “We were also advised to install a higher-level compressor control system. With the same result,” states Armin Niederhuber. Thanks to the retrofit, the operating times of the compressors were adapted much more precisely to the actual air requirements. All information and data obtained from the audit were processed by Festo and made available to all employees on the web-based Festo Energy Saving Services Portal, including open points on potential savings. “Everyone, from energy management employees to on-site workers and mechanics, can access it and see what needs to be done where.” Real-life application Sustainability Automation Compressed air energy efficiency audit
Highlights 2025 Sustainability 28 – 29 Joint success Thanks to the joint partnership between Gessner and Festo, further collaborative steps were taken after the audit to reduce energy consumption, such as a selection of recommendations for suitable compressors. As for the energy expert Niederhuber, downstream leakage detection also led to a surprising discovery: “We wouldn’t have thought that the static consumption of our positioners was in the mid five-digit range.” As a result, all positioners were systematically replaced with more energy-efficient models. “The Festo Energy Saving Services have definitely been worthwhile for us. The transparency, the new ideas, and the projects that they resulted in have been a huge benefit to us.” With the help of Festo Energy Saving Services, Gessner has been able to make substantial savings on energy costs, while at the same time increasing production stability and achieving the environmental protection targets it has set itself. > www.festo.com/ess/audit As part of a leakage detection program from Festo that took several days and during which the problem was systematically rectified, Gessner was able to save 30,000 euros per year in compressed air costs at its plant. Working in partnership: From the joint inspection of the systems to the analysis and evaluation. (Armin Niederhuber, Energy Management Expert at Gessner, left, and Heiko Fleischhacker, Certified Auditor from Festo). Maximum transparency: The Festo Energy Saving Services Portal provides a clear overview of all data for optimizing compressed air systems. > www.neenah-gessner.de
2 Hydrogen
Highlights 2025 Hydrogen 30 – 31 “Tomorrow’s energy is water that has been broken down by electric current. The elements of water thus decomposed, hydrogen and oxygen, will secure the earth’s energy supply for the unforeseeable future.” Jules Verne, 1875 The goal of net zero requires a transition from fossil fuels to renewable energies. Sustainably produced hydrogen is of groundbreaking importance in energy-intensive production facilities such as the steel industry and for the mobility transition, too. Producing hydrogen via electrolysis, transporting it, or using it in many different applications – the demand placed on automation in all these cases is high. Thanks to its experience in gas processing and automation solutions for the production, infrastructure and use of hydrogen, Festo supports companies along the entire value chain.
Hydrogen is ... • 14 times lighter than air • Colorless and odorless, non-toxic • Non-flammable in pure form • Highly flammable with oxygen Gaseous up to -253 °C Liquid at -252 °C Solid at -259 °C Hydrogen was described by its discoverer Cavendish (1731, Nice – 1810, London) as “flammable air”. Chemist de Lavoisier (1743, Paris – 1794, Paris) baptized the gas “hydrogène”. 2.9% of the earth’s crust consists of hydrogen. 75% of the mass of our solar system is hydrogen. 90% of all atoms in the universe are hydrogen atoms. Hydrogen occurs in nature only in bound form, including in water (H2O), hydrocarbons such as natural gas, or crude oil, or in minerals. Hydrogen is key for future energy systems and can be used directly as an energy source, e.g., as a component for aircraft fuels. Green hydrogen Origin: Obtained from water through electrolysis using electricity from renewable energy sources. Carbon emissions: None Blue hydrogen Origin: Fossil natural gas Carbon emissions: Up to 90% can be stored Grey hydrogen Origin: Fossil natural gas Carbon emissions: About 10 t CO2 per ton of H2
Highlights 2025 Hydrogen 32 – 33 2030 2050 1 ton of hydrogen provides 33,330 kWh of energy and is enough to supply seven households with electricity for a year. Fuel of the solar system 600 million tons of hydrogen fuse into helium every second inside the sun and thus supply the solar system with energy. Hydrogen is not freely available on earth and is produced using primary energy (e.g., wind or solar energy). Element of extremes Hydrogen is the lightest element and also has a high energy density: Hydrogen 33.3 kWh per kg Gasoline 12.0 kWh per kg Natural gas 10.6 – 13.1 kWh per kg “Green hydrogen is the central building block of the energy transition; it is particularly essential for storing and transporting large quantities of energy.” Dr.-Ing. Max Ellerich, Solution Manager H2 Production, Neuman & Esser (manufacturer of PEM electrolyzers with over 100 years of experience in hydrogen plant construction) Hydrogen energy storage: When hydrogen is produced using renewable energies, CO2-neutral energy becomes available for e.g., chemical and steel production (sector coupling) or as fuel for transportation. > 40 gigawatts: That is the electrolysis capacity for producing green hydrogen that the EU hydrogen strategy is aiming for by 2030. > 85 billion euros: The market volume of the hydrogen industry expected in the EU by 2030. > 38 measures: The number of measures the German Ministry for Economic Affairs and Energy is planning to introduce by 2030 to make hydrogen usable as an energy source for the energy transition. > 20%: The EU’s goal for covering European energy consumption with hydrogen by 2050. > 160 million tons of green hydrogen could be produced worldwide in 2050, according to forecasts.
Ready-to-install control cabinet: Complete with explosion protection and functional safety (SIL). Electrolyzers are the central element along the hydrogen value chain. The systems that split water into hydrogen and oxygen are key components in numerous industries. Complying with the required functional safety (SIL) and limiting risks are therefore crucial. This can be achieved by using suitable products and solutions. An automation concept that precisely matches the electrolyzer is therefore decisive for efficient, safe, and long-term operation. Festo offers a wide range of components that meet these requirements. Safety as the top priority Hydrogen is a colorless, volatile and non-toxic gas, but it is very flammable and is processed at high pressure. Electrolyzers therefore pose several challenges in terms of safety. To get the green hydrogen produced to a point where it can be used, it has to be made transportable, for example by compressing it in a compressor station. The safety of a system is also important in the event of malfunctions or faults. Festo offers numerous products that are specially certified for use in potentially explosive atmospheres and in accordance with the SIL standard to IEC 61508, such as the sturdy and corrosion-resistant solenoid valves type VOFC and VOFD. The functional safety of electrolyzers is therefore essential to make industrial processes safe, efficient, and environmentally friendly. Producing energy in an environmentally friendly way is one of the greatest challenges of our time, and this is where green hydrogen plays an important part. It will have a decisive role to play in the future supply of energy and the reduction of carbon emissions in energy-intensive industries. Numerous safety regulations must be observed when expanding hydrogen production capacities and the necessary infrastructure. Depending on the specific requirements and characteristics of production, different solutions are possible, such as centralized or decentralized automation solutions, compact control cabinet systems or flexible, modular concepts. > www.festo.com/hydrogen Hydrogen Automation solution for green hydrogen production
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