The path to net zero emissions can be complex – how to start and what actions to take for more sustainable operations. Five years ago, ABB launched the Mission to Zero™ program to kickstart this journey at a grassroots level. From applying technologies backed by ABB’s digital solutions to integrating renewables, 20 manufacturing sites have led the way in cutting emissions and energy consumption, with some even ramping up production. Here are the top five learnings from Mission to Zero sites across the world:
Engaged employees make progress possible. That’s why Mission to Zero site teams also find creative ways to connect employees to their shared net zero mission. It often starts with why sustainability efforts matter – from reducing impact on the planet to meeting customers’ needs for more sustainably produced products. It is also critical to empower employees to take an active role in finding sustainable solutions.
For example, Nogales, Mexico employees organize “sustainability treasure hunts” to uncover energy-savings opportunities. Teams look for lights and equipment left on, air leaks and more, then create an energy and cost-saving plan based on their findings. Employee-driven improvements such as installing an automated compressor, energy monitoring and control systems and solar panels have reduced emissions by 86%.
In Västerås, Sweden, a cross-functional employee sustainability group acted on their ideas to help increase site energy efficiency by 37%. Actions included making e-bikes available for employees, investing in energy-efficient compressors, and reprograming and replacing ventilation fans.
“The motivation and inspiration for Mission to Zero comes from ABB employees, and we’ve seen a ripple effect,” said Anders Jakobsson, Mission to Zero program lead.
Success stories have spread organically, igniting interest at other sites. Mission to Zero program leads also connect site teams with similar needs and obstacles to scale successes.
“Having the head start of a knowledge base from a community of sites who face similar challenges is a huge benefit,” said Lucas Bergmann, sustainability and infrastructure manager, at ABB’s Lüdenscheid, Germany facility.
Buildings consume more than 30% of the world’s energy and contribute almost 40% of global carbon emissions. However, 80% lack the automation or digitization needed to drive improvements.
Digital technologies can provide the quickest path to knowing where to start when it comes to meeting carbon reduction benchmarks.
“ABB Ability™ makes opportunities visible, from LED lighting and energy-efficient heat pumps to PV panels,” Jakobsson said. “With ABB Ability, everyone who enters the facility can see a breakdown of energy consumption data by building or equipment on a flat-screen display.”
For many Mission to Zero sites, ABB Ability™ digital solutions have provided real-time insights to monitor progress and identify additional opportunities to enhance operational efficiency, safety and sustainability.
Mission to Zero teams have been resourceful, integrating renewable energy and recycling waste heat. The Santa Palomba, Italy facility did not have enough roof space for a proper PV system, so the team partnered with a neighboring business to install solar panels there and buy back the electricity. Similar power purchasing agreements are in place in Europe and Mexico.
Additionally, sites in Nogales (Mexico), Porvoo (Finland) and Rakovski (Bulgaria) are recycling waste heat from manufacturing processes to store in heat pumps and redirect into district heating. These recovery efforts have helped reduce gas consumption by up to 90%.
One sustainable improvement can inspire another. This was the case at the Nashik, India facility, which expanded its Mission to Zero efforts to include water conservation in a water-scarce region. The Nashik facility was certified water positive by the GRIHA Council (Green Rating for Integrated Habitat Assessment) for returning more water than it uses. The plant has cut its water consumption by 30% through innovative measures including drip-based irrigation and enhanced meter monitoring and analysis.
Local communities are benefiting, too. ABB with help from partners commissioned rainwater harvesting structures for farmers and locals in nearby rural villages.
An increasing number of sites are also achieving zero waste to landfill, and receiving validation from UL Solutions, a trusted certifier in the industry. At the Vaasa, Finland site, 100% of the site’s waste is reused, recycled or composted. As an example, the Vaasa team partnered with Stena Recycling to transform wasted wood from packaging and damaged pallets into woodchips for composted soil.
By creating real-life case studies of low-carbon manufacturing facilities, ABB is showing others how to meet their sustainability targets. The Xiamen, China facility hosts an annual Sustainability Week to share its Mission to Zero commitments and solutions.
“We’ve made our site a smart showcase to educate customers, suppliers, governments and partners on sustainable operations,” said Jason Ouyang, digital system manager, ABB Xiamen.
Governments and customers are taking note of how ABB sites are reducing environmental impact. Nashik, Xiamen and Dalmine(Italy) have been recognized as best-practice sites for sustainable manufacturing. ABB’s largest customer in Finland named the Porvoo (Finland) operations as sustainable supplier of the year in 2023.
