The top articles in Control Engineering this month covered topics like PID tuning, modernizing plants, the Engineering Leaders Under 40 and physical AI security.

From optimizing PID control to securing the future of physical AI, Control Engineering’s most-read articles in September 2025 showcase the industry’s ongoing evolution. Readers explored how leading companies are modernizing operations — from Eaton’s $340 million transformer expansion to Shell’s software-defined refinery controls — while celebrating the next generation of innovators through the Engineering Leaders Under 40 program. In-depth technical insights on noisy processes, sticking valves and motion control efficiency rounded out the month’s coverage. Dive in to see what’s driving innovation, leadership and transformation across today’s control engineering landscape.

1. Powerful new site expands transformer capacity in South Carolina

Eaton will invest $340M in its Jonesville facility, creating 700 jobs and expanding U.S. production of three-phase transformers.

2. Powering Progress: Meet the 2025 Engineering Leaders Under 40

Celebrating 35 engineering professionals who are driving transformation, mentorship, and excellence across the industrial landscape.

3. Shell modernizes refinery control with software-defined automation

Schneider Electric demonstrates how the hardware agnostic distributed intelligence of its EcoStruxure Automation Expert platform is creating a flexible control architecture for manufacturers.

4. 2025 Engineering Leader Under 40: Prashant Ghadge, 39

Prashant brings 15 years of expertise in designing compressor packages with advanced controls for system protection and capacity management. His work spans integrating PLC panels with pressure, temperature, vibration, and speed sensors, as well as selecting motors and actuators and defining sequences of operation.

5. PID spotlight, part 21: Noise: Can I tune around it?

I have a noisy process. How does that affect my PID controller? Can I tune my controller like I always do, or do I have to change tuning because of the noise?

6. PID spotlight, part 20: How to tune with sticking control valves

Sticking control valves warp loop-tuning results. Is that a nuisance or a potential disaster? Which way does a sticking valve warp the results and can we compensate? See three things about loop tuning with a sticking control valve.

7. How to create a physical AI security, safety framework

Explore the security and safety aspects of the emerging industry known as physical artificial intelligence (AI). As physical AI evolves from concept to reality, understanding its implications for human safety and security becomes critical.

8. 2025 Engineering Leader Under 40: Hugo Dozois-Caouette, 33

Hugo is redefining what modern maintenance and operations software can do for frontline industries. As co-founder and CTO of MaintainX—one of North America’s fastest-growing technology companies—he has architected a platform used in more than 11,000 factories and facilities worldwide. His leadership in building AI-powered, mobile-first tools has helped unlock data visibility where processes were once paper-based or siloed.

9. Control Engineering reveals new 2026 topics from subscriber research

Control Engineering 2026 editorial calendar, determined by subscriber research, is provided in this document. Link to how to contribute and full media kit.

10. How to double production with people, technologies, motion controls

Windsor Door transformed operations with a culture of continuous improvement, innovation, and investments in people and operations, including $21 million in a new high-speed production line that doubled plant production and efficiency. Advanced motor technologies improve motion control quality and reliability.

Check out the top articles from September here.