- ABB Bulgaria’s Rakovski factory achieves 1250* tonnes CO2e reduction and saves 22 percent of energy consumption as part of its Mission to Zero™ journey
- The factory improved energy intensity by 43 percent by using sustainable approaches in its production operations
ABB’s Electrification factory in Rakovski, Bulgaria is taking a major step towards net zero operations by reducing CO2e by 1250 tonnes. This was largely driven by energy optimization measures such as 100 percent metered and controlled energy, a building management system, installation of heat pumps, LED lighting upgrades, and electric vehicle (EV) charging points.
The factory reduced the energy consumption of its operations by 22 percent but also increased production revenue, which improved the energy intensity significantly by 43 percent compared to a 2019 baseline. The 39,000-square-meter plant consists of two production buildings and manufactures low and medium-voltage products for data centers, industrial and manufacturing plants, critical infrastructure, and buildings.
Since 2021, the site team has been taking steps to support ABB’s Sustainability Agenda. Their first significant step was to upgrade all conventional lighting in both production halls with energy-saving LED lighting fixtures and integrate the ABB i-bus KNX system for intelligent lighting control.
The following key milestone in the facility’s Mission to Zero™ journey was the installation of ABB AbilityTM Energy and Asset Manager solutions at both units as this innovation empowered safer and smarter operation through energy efficiency optimization and predictive maintenance. The system provides real-time data and eases decision-making by allocating costs of energy resources by groups - production, lighting, heating, ventilation, and air-conditioning (HVAC) and administration. The installation of ABB’s solutions and the implementation of sustainable initiatives at the Rakovski plant were instrumental in achieving the ISO 50001 certification.
To reduce HVAC energy consumption and up to 80 percent of CO2e emissions from gas usage, the factory had heat pumps installed last year along with centralized control and monitoring for heating and cooling and a fluid distribution system. The controlling and monitoring of those systems is operated by ABB’s building management system - ABB Cylon®, which was installed in both buildings at the beginning of 2024. The end-to-end solutions track and forecast energy consumption, which will facilitate the future planned use of renewable energy and ensure a stable energy supply.
“Our end-to-end solutions contribute to the effective tracking and forecasting of energy consumption,” said Mike Mustapha, President, ABB Electrification’s Smart Buildings Division. “The achievement in our Bulgarian operations not only showcases how we reduce carbon emissions in our own built environment, but it underscores our ability to help customers and partners achieve their own sustainability goals.”
To meet ABB’s 2030 fleet electrification commitment, the Rakovski branch started the conversion of its vehicle fleet to electric vehicles. It installed 17 AC and DC EV charging stations, supporting EV charging for the wider community and for passing traffic.
These achievements represent a key milestone in ABB Bulgaria’s net zero journey, qualifying them to be designated an ABB Mission to Zero™ site. The ABB Mission to Zero™ program supports the company’s commitment to reduce Scope 1 and Scope 2 GHG emissions by 100 percent by 2050*. Driven by local teams, sites focus on improving efficiencies through energy generation, management, and storage using ABB’s innovative technologies and third-party integration.
*Compared to 2019 baseline
ABB is a technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. The company’s solutions connect engineering know-how and software to optimize how things are manufactured, moved, powered and operated. Building on over 140 years of excellence, ABB’s more than 105,000 employees are committed to driving innovations that accelerate industrial transformation. www.abb.com
ABB Electrification is a global technology leader making efficient and reliable use of electricity from source to socket possible. With more than 50,000 employees across 100 countries, we collaborate with our customers and partners to solve the world’s greatest challenges in electrical distribution and energy management. We help businesses, industry, and consumers run their facilities and homes efficiently and reliably. As the energy transition accelerates, we are electrifying the world in a safe, smart and sustainable way. go.abb/electrification
