In today’s fast-evolving global marketplace, food and beverage manufacturers are operating under increasing pressure. From maintaining food safety and traceability to meeting sustainability targets and adapting to volatile supply chains, the list of food production vulnerabilities are growing. Digital transformation offers a compelling solution – and at the heart of this shift lies IO-Link technology.
IO-Link, a point-to-point communication protocol for sensors and actuators, is empowering manufacturers to modernise their operations, reduce downtime, and respond more intelligently to production demands. With built-in flexibility, plug-and-play simplicity, and rich data capabilities, it’s becoming a cornerstone of next-generation manufacturing.
Addressing a shifting landscape
Australia’s food and beverage manufacturing sector accounts for 23 per cent of the nation’s manufacturing GDP, with the industry employing more than 270,000 people across the country. Despite its size and contribution, the industry is under pressure. Environmental and labour challenges, combined with geopolitical unrest and economic instability, have created vulnerabilities in the food supply chain.
The COVID-19 pandemic exposed fragilities in global and domestic logistics networks. Extreme weather events, such as floods and bushfires, have added to the strain. These factors have spurred a renewed focus on local production, efficiency, and resilience.
Overlaying this is a tightening regulatory framework. The introduction of the Treasury Laws Amendment (Financial Market Infrastructure and Other Measures) Bill 2024 will make climate-related disclosures mandatory for large businesses in Australia. Food and beverage producers will need to demonstrate energy and water efficiency, emissions reductions, and environmental responsibility.
And then there’s food safety, which is an ever-present concern. A single contamination incident can trigger product recalls, legal consequences, and lasting reputational damage.
A recent industry study found that 38 per cent of Australian F&B leaders cited food safety as their primary concern, underscoring the need for preventative solutions.
The role of IO-Link in modern manufacturing
To tackle these varied challenges, many producers are embracing digitalisation with IO-Link emerging as a key enabler. Developed as a standardised, open technology (IEC 61131-9), IO-Link facilitates bi-directional communication between field devices – like sensors and actuators – and control systems, unlocking real-time process insight.
Where traditional analogue systems are limited by noise, complex wiring, and minimal feedback, IO-Link offers:
- Seamless integration with existing PLCs, fieldbuses, and control systems.
- Greater accuracy in data collection, including temperature, pressure, flow, and level.
- Simplified installation and maintenance due to standardised, unshielded cables.
- Remote configuration and diagnostics, reducing the need for physical intervention.
“IO-Link allows you to turn your sensors into intelligent data sources. It helps businesses meet strict quality, safety, and environmental standards while making their processes leaner and more resilient,” said Freddie Coertze, national IoT business manager at ifm Australia.
Real-time data for smarter operations
One of the advantages of IO-Link is the ability to capture and utilise real-time data.
Whether it’s monitoring refrigeration temperatures in a dairy plant, tracking flow rates in a beverage bottling line, or measuring the pressure in a meat processing facility, IO-Link provides immediate insight.
This enables plant managers to respond proactively rather than reactively. For instance, if a valve begins to drift out of range, IO-Link sensors can detect the change and trigger an alert before the issue escalates. This supports predictive maintenance, one of the most valuable tools for reducing unplanned downtime and improving asset reliability.
The addition of Y-Path technology – a communication route allowing process and service data to be accessed simultaneously – further enhances visibility.
This dual-channel setup allows for condition monitoring while production continues uninterrupted, a boost for continuous processing industries.
A success story: Nuttelex Food Products
Nuttelex, a Melbourne-based manufacturer of plant-based spreads, is one example of an Australian business embracing digital transformation with IO-Link.
With a commitment to allergen-free production and high-quality standards, Nuttelex turned to ifm for sensor automation solutions. IO-Link-compatible sensors were deployed across various parts of the plant, streamlining data collection and improving repeatability.
“We needed more control over our processes, more visibility into our machines, and less downtime. ifm’s technology, especially the IO-Link system, has helped us achieve that while future-proofing our operations,” said Mitchell Johnstone, systems engineer at the company.
Supporting sustainability and ESG compliance
As environmental legislation tightens, manufacturers must do more than meet production goals, they must measure and minimise their environmental impact.
IO-Link sensors can monitor energy usage, water flow, temperature changes, and machine efficiency in real time. This data can be aggregated to produce emissions reports, assess water efficiency, and inform maintenance strategies that reduce waste.
With automatic data logging, IO-Link also supports regulatory compliance. Accurate, traceable records simplify audit processes and demonstrate proactive environmental stewardship.
“Sustainability is no longer just good practice – it’s a business imperative. IO-Link delivers the transparency businesses need to hit their targets and show measurable progress,” said Coertze.
Enhancing food safety and hygiene
From raw ingredient handling to final packaging, food safety is non-negotiable. IO-Link sensors can provide precise, consistent monitoring of process-critical values such as temperature, humidity, pressure, and cleanliness.
Any deviation can trigger an immediate alert or corrective action. In one example, a meat processing plant used IO-Link to ensure temperature thresholds in refrigerated storage were never breached.
This level of precision helps eliminate human error and supports HACCP (Hazard Analysis and Critical Control Point) compliance.
Additionally, IO-Link’s compatibility with hygienic design standards and IP-rated devices makes it suitable for washdown environments, common in food processing.
Wireless IO-Link and the future of automation
The future of IO-Link is wireless. IO-Link Wireless eliminates the need for physical cabling between sensors and masters, expanding the technology’s use in rotating, mobile, or hard-to-reach applications.
This innovation is already making headway in intralogistics and warehouse automation, but its potential in food manufacturing is vast, from robotic arms on packing lines to mobile
cleaning systems.
There’s also a growing trend towards integrating functional safety directly into IO-Link devices. This convergence will simplify control architectures, reduce wiring complexity, and strengthen plant-wide safety protocols.
“We’re heading towards fully connected, intelligent plants. IO-Link is the gateway to that reality, bringing together efficiency, compliance, and innovation,” said Coertze.
Conclusion
For Australia’s food and beverage manufacturers, digitalisation is more than a competitive advantage, it’s a necessity. IO-Link technology provides a cost-effective and scalable path to smarter operations, improved safety, and sustainability compliance.
By enabling real-time monitoring, predictive maintenance, and seamless integration with existing systems, IO-Link is helping producers navigate a complex landscape with confidence
and clarity.
Whether you’re a small producer or a large-scale manufacturer, investing in smart sensors and communication protocols like IO-Link is a step towards future-ready operations.
Have questions or interested to learn more about how IO-Link might benefit your operation? Come see ifm at FoodTech 2025.