Adopting Smart Solutions to Reduce Carbon Emissions in Manufacturing

Peter Krarup, Senior Vice President of Group Operations at Grundfos

The manufacturing industry needs to move the dial on decarbonisation. In the UK, the industry accounts for 17 per cent of the country’s greenhouse gas emissions. Globally, it is responsible for one-fifth of the world’s total emissions. Globally, it is responsible for one-fifth of the world’s total emissions.

To reach net zero, the industry must minimise its mammoth carbon footprint. Manufacturers can now tackle emissions head-on by making a difference with just three impactful changes. now tackle emissions head on by making a difference with just three impactful changes.

Addressing Excessive Energy Consumption

Considering that the global manufacturing industry accounts for the majority, 54 per cent, of the world’s energy consumption, it is perhaps no shock that the sector is responsible for such a proportionally large volume of greenhouse gas emissions.

Yet, the magnitude of manufacturers’ carbon emissions can be reduced significantly by boosting efficiencies through the adoption of smarter water and energy solutions.

As it stands, many manufacturers run outdated equipment across their production processes. Swapping energy-intensive, inefficient systems for smarter solutions can optimise energy and water use across the production chain and curb carbon output.

When UK soft drink manufacturing giant Britvic set out to upgrade the water supply in its Rugby facility to deliver the correct, varying amounts of water at the correct pressure whilst slashing energy costs and carbon emissions, Grundfos designed and deployed a bespoke solution that increased water flow by 70 per cent and reduced energy costs by 45 per cent. The efficient pumping system led to 69,500 euros in energy savings annually and  and reduced energy costs by 45%. The efficient pumping system led to 69,500 euros in energy savings annually and represented a return on investment of less than two years. represented a return on investment of less than two years.

As the Britvic case underscores, when manufacturers make the conscious decision to swap energy-sapping equipment for more efficient solutions, they can unlock the ability to axe their energy consumption and in turn, bring down their greenhouse gas emissions.

Driving the Uptake of Digital Solutions

Manufacturers can also boost efficiencies and reduce carbon emissions by embracing the benefits of digitalised solutions, such as such as electronic motors, or e-motors.

In the manufacturing sector, motor-driven systems account for up to 64 per cent of electric energy consumption. To meet carbon-reduction targets, manufacturers should set out to smarten their motor technology.

“Employing smarter energy and water solutions throughout the manufacturing process has the benefit of reducing energy consumption and slashing operational costs and critically decreasing carbon emissions and pushing the needle on net zero”  

Indeed, e-motors will play an enormous role in alleviating excessive energy consumption in the manufacturing sector by improving the efficiency of energy systems and reducing CO2 emissions. In 2020 alone, Grundfos’ e-motors reduced CO2 emissions by an astounding 270,000 tons.

By employing digital solutions such as e-motors, manufacturers can make strides in cleaning up their carbon emissions, reducing operational costs and optimising their manufacturing processes. It is a clear win for both industry and the planet.

Reducing Carbon Emissions by Curbing Water Consumption

Given the intertwinement between water and energy, manufacturers should also address potential points of inefficient water consumption along the production chain to reduce emissions. Notably, minimising water consumption is an underacknowledged, but vitally important aspect of reducing carbon emissions.

According to the Chartered Institution of Water and Environmental Management, water use constitutes around 6 per cent of the UK’s carbon emissions. Reducing water consumption by 10- of the UK’s carbon emissions. Reducing water consumption by 10-12% could play a role in minimising the UK’s carbon footprint by cutting overall emissions by around 0.5%. emissions by around 0.5 per cent.

Take the case of Arla Foods, one of the leading players in the global dairy market, as a prime example of how manufacturers can make the move to more efficient water consumption. 

Arla set out to achieve its goal of reaching net-zero emissions by 2050. To make this happen, the dairy giant endeavoured to first lower its carbon emissions by 63 per cent at 60 dairies worldwide by 2030.

By installing new intelligent pumps for chilled and iced water applications at the company’s Westbury facility in the UK, Arla was able to significantly improve the efficiency of the factory’s water use.

The intelligent pumps contributed to 481,800 kWh in energy savings, amounting to 194 tons of carbon dioxide saved for their ice and chilled water systems.

The upgrades to intelligent pumps also reaped an impressive return on investment of fewer than two years and made Arla’s net-zero ambitions even more attainable.

As the Arla case exemplifies, manufacturers can shrink their carbon output and enjoy long-term financial benefits by investing in equipment that optimises their water consumption. 

From Complacency to Carbon Reduction

The manufacturing industry should not be complacent about its status as a top carbon emitter. Rather, manufacturers need to urgently evaluate the efficiency of energy and water solutions used across the production chain and look to upgrade inefficient, carbon-intensive technologies.

Employing smarter energy and water solutions throughout the manufacturing process has the benefit of reducing energy consumption and slashing operational costs and critically decreasing carbon emissions and pushing the needle on net zero. 

By addressing inefficiencies and reducing energy consumption, employing digital solutions, and optimising water consumption, manufacturers can play their part in making progress towards global net-zero commitments.

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