Automating Hydrogen Fuel Production: Scalable Solutions for a Decarbonised Future

Green hydrogen production at scale requires a considered approach to process control, specifically whether to adopt a centralised, decentralised, or hybrid automation system.

Published: 11th November 2025 | Issue 102

According to the World Economic Forum, the world needs to produce approximately 530 million tonnes of green hydrogen annually - roughly six times current hydrogen production levels - to achieve net-zero emissions by 2050.1 Hydrogen production must move from pilot to large-scale production at an unprecedented pace to meet this demand.

Choosing the right automation concept for hydrogen electrolysis at scale is crucial for success. It can significantly impact downstream costs, performance and efficiency. Engineers need to consider the advantages and disadvantages of adopting a centralised, decentralised, or best-of-both hybrid automation system. There are significant differences between these automation concepts for electrolysers, relating to aspects such as data management, compatibility, flexibility, modularity, and scalability.

Centralised automation, where a single controller manages all electrolyser skids, offers streamlined data management and efficient resource use. It’s typically ideal for large, fixed installations with well-defined parameters. However, it can be vulnerable to single-point failures and may struggle with scalability.

Decentralised systems, by contrast, assign control to individual modules, boosting fault tolerance and adaptability. These systems are well-suited to modular, remote, or evolving operations. However, complexity can be an issue, particularly when decentralised units are sourced from different manufacturers and there is no consistent application of common standards. This can also cause difficulties in integrating with other operating and IT systems.

Festo’s communications-neutral platforms, which are compatible with Fieldbus, Profibus, and Ethernet, help overcome these hurdles by bridging the gap between centralised and decentralised models. Its CPX-MPA platform supports centralised control with integrated I/O and pneumatic valves, while the Festo AP platform enables decentralised control with mechanically separated submodules sharing a common data connection. This modularity allows engineers to tailor automation to specific plant needs, without sacrificing performance or compatibility.

Importantly, Festo’s systems-neutral approach means users can source all the automation components necessary to automate an electrolyser from a single supplier, from powerful operator units and modular controllers to remote I/O, valve terminals and actuators. This not only simplifies procurement and commissioning but also reduces capital and operating costs, accelerating the transition to affordable, sustainable hydrogen.

More insights into centralised, decentralised and hybrid automation solutions for hydrogen production, plus a handy checklist to help determine which automation approach will suit your application best, are covered in Festo’s blog: www.festo.com/centralised_decentralised_H2_production