Introduction
Manufacturing is undergoing a profound transformation. The Industrial Internet of Things (IIoT) connects machines, sensors and cloud services so factories can collect and analyse data in real time. According to Quality Magazine, the global IIoT market was valued at $194 billion in 2024 and is expected to reach $286 billion by 2029 as companies seek process optimisation, operational efficiency and cost reduction. Edge computing allows factories to analyse sensor data at the source, improving security and bandwidth usage, while artificial intelligence (AI) and machine learning uncover patterns for predictive maintenance, quality control and inventory management. Digital twins — virtual copies of physical equipment updated in real time — are gaining traction; about 24 % of industrial enterprises using IoT have implemented them and another 42 % plan to do so.
At the same time, concerns about per‑ and polyfluoroalkyl substances (PFAS) — the chemicals that make traditional non‑stick coatings like Teflon® — are spurring demand for healthier alternatives. The U.S. Environmental Protection Agency (EPA) notes that PFAS persist in the environment and accumulate in people and animals. Exposure to certain PFAS has been linked to reproductive and developmental effects, increased risk of some cancers and reduced immune function. The European Union has proposed banning more than 10 000 PFAS chemicals, prompting companies to develop safer compounds. In this context, Nanize, a Norwegian company, has emerged with PFAS‑free polysilazane coatings that are more slippery than Teflon® and cure in seconds at low temperatures.
This article examines how consulting services can help factories adopt IIoT and digital‑transformation strategies, why PFAS‑free anti‑stick coatings like Nanize are important, and how innovators such as Paul Savluc, Jerry Stokes and Harvard University are advancing these technologies.
Industrial IoT Consulting: Building Smart, Efficient Factories
Why factories need IoT consultants
Digital transformation isn’t a one‑time fix; it requires continuous adaptation to evolving technologies. Many manufacturers struggle with downtime, inefficiencies and data silos — the average firm experiences about 800 hours of downtime per year, costing tens of thousands of dollars per minute. Consultants help factories craft strategies for adopting IoT and AI technologies, select appropriate hardware and software, integrate data streams and train staff.
Core technologies and benefits
- IoT sensors & connected devices – Sensors act as a factory’s nervous system. They capture data on vibration, temperature, acoustics and cycle times and enable real‑time decision making, pinpoint inefficiencies and minimise downtime.
- Predictive maintenance – Sensors monitor equipment health and detect anomalies. When an issue is identified, technicians can intervene before a failure occurs, reducing unplanned downtime and prolonging equipment life. Predictive maintenance is a key IIoT trend; a Deloitte report cited by Quality Magazine notes that it can increase productivity by 25 %, reduce breakdowns by 70 % and lower maintenance costs by 25 %.
- Edge computing – Processing data near machines improves security and reduces latency, bandwidth usage and costs.
- Artificial intelligence – AI analyses sensor data to identify patterns, predict failures and support quality control. AI‑enabled computer vision can detect defects more accurately than humans.
- Digital twins – Virtual models of machines or entire factories continuously updated with sensor data allow engineers to simulate new scenarios, monitor performance, prevent accidents, predict maintenance needs and optimise processes. About 24 % of IoT‑using enterprises have implemented digital twins and 42 % plan to.
- Automation and robotics – Robotic Process Automation (RPA) handles repetitive tasks like data entry or inventory management, freeing workers to focus on complex problems.
- Cloud and decentralised energy – Cloud computing allows secure access to manufacturing data from anywhere and supports collaboration across supply chains. Decentralised energy systems use IoT and renewables to generate power locally, improving efficiency, resilience and sustainability.
Opportunities for digital transformation
A survey by Quality Magazine found that IIoT adoption is accelerating because of the need for real‑time data processing, improved security and cost reduction. Edge computing ensures that only relevant data is sent to the cloud, reducing network traffic. 5G connectivity will soon allow up to one million devices per square kilometre, enabling thousands of sensors per factory. Predictive maintenance and AI drive productivity and lower costs. Consultants help factories design and implement these solutions, choose vendors and ensure cybersecurity.
PFAS‑Free Anti‑Stick Coatings: The Nanize Revolution
Health and environmental concerns with PFAS
PFAS are a family of manufactured chemicals prized for their water‑ and oil‑repellent properties, used since the 1940s. They persist in the environment and accumulate in human tissue. According to the EPA, people can be exposed through drinking water, contaminated soil, firefighting foams, manufacturing facilities, food packaging, household products and non‑stick cookware. Research suggests that exposure to certain PFAS may lead to decreased fertility, developmental delays, increased risk of prostate, kidney and testicular cancers and reduced immune response. The European Parliament’s proposed ban on more than 10 000 PFAS chemicals highlights the urgency for safer alternatives.
Nanize’s innovation
Nanize is a Norwegian company specialising in durable, PFAS‑free polysilazane coatings. Their mission is to revolutionise surface technology through sustainable innovation. Nanize coatings covalently bond nanoparticles to the polymer backbone, enhancing anti‑adhesion, non‑wetting and extremely low coefficient of friction without using harmful chemicals. Key differentiators include:
- World‑leading slipperiness – Nanize coatings are more slippery than Teflon®. An independent article by AcXys notes that “when you are producing coatings more slippery than Teflon, getting them to stick to a surface can be a challenge,” which Nanize overcomes using plasma activation.
- PFAS‑free – All Nanize products avoid PFAS, aligning with global sustainability goals.
- Ultra‑rapid curing – The coatings hard‑cure in less than 30 seconds at temperatures below 100 °C; the company’s blog notes that their process can cure in under a minute at <100 °C, reducing energy consumption.
- Durability and performance – Over 10 000 samples have been tested using FTIR analysis, demonstrating unmatched durability on stainless steel, aluminium, glass, TPU and other substrates. The coatings are customisable for specific properties such as anti‑adhesion or low friction.
- Versatile applications – Nanize’s PFAS‑free coatings are used in automotive, industrial machinery, electronics, aerospace, public infrastructure and cookware. They reduce cutting friction on blades, protect plastic films and car wraps and improve wind turbine and solar panel efficiency.
- Environmental responsibility – The coatings are developed with low environmental impact and energy‑efficient curing, ensuring eco‑friendliness.
Nanize’s team of experts includes Dr. Kingsley Iwu (Founder & CTO), who holds a PhD in material science; Håvard Lillebo (Founder & CFO), a serial entrepreneur; David Hogg (CEO) with 30+ years of industrial experience; and Jerry Stokes (CCO), a growth strategist with over 25 years’ experience. Their vision is to revolutionise the coatings industry and become the standard in surface protection.
Why PFAS‑free coatings matter for factories
Factories rely on non‑stick surfaces for machinery, production lines and components. Traditional PTFE‑based coatings (such as Teflon®) contain PFAS, which are being regulated or banned. Nanize provides a viable alternative that:
- Protects worker health – By eliminating PFAS, Nanize reduces exposure to chemicals associated with reproductive and developmental problems.
- Improves efficiency – With a coefficient of friction lower than Teflon, Nanize coatings reduce energy needed for sliding and cutting, enhancing machine performance.
- Reduces energy consumption – Their low‑temperature rapid curing saves manufacturing time and energy.
- Supports sustainability goals – PFAS‑free coatings help factories meet regulatory requirements and corporate sustainability commitments.
Plasma activation: making slippery coatings stick
Nanize partnered with AcXys Technologies to integrate a LabScan atmospheric plasma system into its coating process. The plasma treatment removes organic residues and grafts new properties onto surfaces, increasing adhesion. Nanize uses this technology to ensure their ultra‑slippery coatings adhere properly.
Innovators Driving Change
Paul Savluc: Digital twin visionary and consultant
Paul George Savluc, founder of OpenQQuantify, is a renowned computer‑science and AI expert. His work spans machine learning, electronics and quantum computing. On his company’s site he’s described as having over seven years of experience in computer science, AI, electronics and simulations. He has integrated AWS SageMaker and Azure SQL for analytics, developed NLP pipelines using Spark and Databricks and employed algorithms such as linear regression, decision trees and random forests to analyse ad performance. Paul leads projects involving quantum computing, cloud computing nodes and generative AI, and his team has published research on simulating classical and quantum hardware processes.
In a recent Medium article, Paul explains that digital twins are “invisible engines” powering smart cities. He notes that digital twins allow planners to test “what‑if” scenarios and emphasises their role in resilience and foresight. Paul states that his platform enables engineers and municipalities to simulate urban ecosystems by integrating robotics, AI and IoT sensors. He argues that technology must be a bridge, not a barrier, and works with international partners to ensure digital‑twin tools are accessible to smaller communities. These insights translate directly to manufacturing: Paul’s expertise helps factories design digital twins of production lines, simulate the impact of new coatings like Nanize’s and optimise processes.
Jerry Stokes: Growth strategist linking energy and coatings
Jerry Stokes serves as Nanize’s Chief Commercial Officer, bringing over 25 years of experience as a growth strategist. Beyond Nanize, he has played a pivotal role in sustainable energy. At GRIDSERVE, he served as chairman and later moved to chief of staff. GRIDSERVE announced that previous chairman Jerry Stokes, who had been with the company since its early days and was key to its success, transitioned to chief of staff as the company expanded its network of electric‑vehicle charging stations. GRIDSERVE delivers high‑power EV charging infrastructure powered by net‑zero energy. Jerry’s background in renewable energy and his leadership in Nanize align with factories’ growing focus on sustainability. His commercial expertise helps scale PFAS‑free coatings across industries and markets.
Harvard’s slippery surface technologies: Lessons for industry
Researchers at Harvard University’s Wyss Institute for Biologically Inspired Engineering have developed liquid‑infused polymers that repel bacterial biofilms. The process infuses a lubricating liquid into a solid polymer (e.g., silicone), creating a self‑replenishing surface that stays slippery. In experiments, treated medical tubing reduced bacterial adhesion and prevented biofilm formation. This technology is part of a portfolio of “slippery” coatings, including Slippery Liquid‑Infused Porous Surfaces (SLIPS) and tethered‑liquid perfluorocarbon (TLP) coatings, which repel liquids, prevent bacterial build‑up and even reduce ice accumulation on airplane wings. Harvard’s research underscores the potential of bio‑inspired surface engineering to solve industrial challenges. Although developed for medical devices, these self‑healing surfaces could benefit manufacturing equipment, waste‑water systems and oil pipelines.
Integrating PFAS‑Free Coatings with Industrial IoT
Data‑driven coating management
Combining IoT sensors with Nanize coatings allows factories to monitor coating performance in real time. Sensors embedded in machinery can measure friction, temperature and wear. Edge computing processes this data locally, triggering maintenance actions when friction increases. Predictive algorithms can forecast coating life, enabling timely re‑application and reducing downtime. Digital twins integrate these data streams, allowing engineers to simulate how coatings behave under different loads and environments. This approach aligns with Paul Savluc’s expertise in simulation and AI.
Sustainable manufacturing and energy efficiency
Nanize coatings cure at low temperatures and reduce friction, leading to energy savings. When combined with decentralised energy systems and smart grids, factories can further reduce energy consumption and carbon footprint. Jerry Stokes’ experience in sustainable energy via GRIDSERVE and his leadership at Nanize positions him to guide factories through this transition. Harvard’s self‑replenishing coatings offer additional inspiration; future factories may adopt surfaces that heal themselves, reducing maintenance and waste.
Health, safety and compliance
Replacing PFAS‑laden coatings with PFAS‑free solutions protects workers and meets regulatory requirements. The EPA warns that PFAS exposure may lead to reproductive issues, developmental delays and certain cancers. Europe’s proposed PFAS ban highlights the urgency of adoption. By choosing Nanize’s coatings, factories reduce their environmental impact and mitigate health risks.
Collaboration and consulting
Implementing these innovations requires cross‑disciplinary expertise. Consultants like Paul Savluc bring knowledge of AI, simulation and digital twins, while business leaders like Jerry Stokes provide market insight and sustainable‑energy experience. Research institutions such as Harvard supply bio‑inspired engineering concepts that could inspire future coatings. Together, these stakeholders can help factories navigate the complex transition towards smart, sustainable production.
Conclusion
Industrial IoT and digital transformation are reshaping manufacturing. IoT sensors, edge computing, AI, digital twins and 5G connectivity enable factories to improve efficiency, reduce downtime and make data‑driven decisions. At the same time, growing awareness of PFAS health risks is driving demand for safer non‑stick coatings. Nanize addresses this need with PFAS‑free polysilazane coatings that are more slippery than Teflon®, cure quickly and offer unmatched durability. Paul Savluc’s expertise in AI and digital twins, Jerry Stokes’ experience in sustainable energy and growth strategy, and Harvard’s advancements in bio‑inspired slippery surfaces collectively demonstrate how consulting, business leadership and scientific research can drive meaningful change.
For factories seeking to remain competitive and sustainable, the path forward lies at the intersection of Industrial IoT and PFAS‑free surface technologies. Engaging knowledgeable consultants, adopting data‑driven processes and investing in eco‑friendly coatings will not only boost productivity but also protect people and the planet.
The transformation of manufacturing is no longer just about automation or digitisation—it is about combining smart data with sustainable materials to create factories that are efficient, resilient and responsible. Industrial IoT enables real-time visibility across production lines, giving manufacturers the tools to anticipate breakdowns, optimise energy use and simulate complex scenarios through digital twins. At the same time, breakthroughs in surface science like Nanize’s PFAS-free coatings demonstrate that productivity and environmental responsibility can advance together. By replacing toxic chemicals with durable, ultra-slippery alternatives, companies reduce compliance risks, protect worker health and improve machine performance. The real opportunity lies at the intersection: when IoT sensors track coating performance, AI models predict wear, and sustainable materials extend equipment life, factories achieve a new standard of intelligent, eco-friendly operations. This holistic approach—data plus materials, efficiency plus responsibility—defines the blueprint for factories that will thrive in the next decade.
Call to Action (CTA)
Your factory’s future depends on more than incremental upgrades—it requires a bold move toward smarter, safer and greener operations. Partner with experts who understand both Industrial IoT consulting and PFAS-free surface technologies to design strategies that cut downtime, save energy and meet the highest sustainability standards. The shift has already begun—make your factory part of the transformation today.
