In Dalmine, Italy, a 46-year-old ABB manufacturing facility is proving that energy-efficient factories don’t necessarily have to be new builds.
Built in 1979 as a conventional medium-voltage switchgear and circuit breaker plant, Dalmine became the first ABB site in Italy, and only the fifth globally, to achieve Mission to Zero™ status in 2022. Through a combination of renewable energy sourcing, on-site solar generation, cutting-edge digital monitoring technologies and resource conservation, the 65,000-square meter facility has reduced its emissions by 66%. * The site plans to achieve an 80% reduction in Scope 1 emissions by 2030 and has already reduced its Scope 2 emissions by 100% as of 2019.
“When we started with our Mission to Zero, it was a dream,” said Paolo Perani, Sustainability Manager for the Electrification Distribution Solutions Division. “But it quickly became our reality.”
Dalmine has long sourced 100% of its electricity from certified renewable energy sources like wind, hydro and solar through Enel Green Power, but Mission to Zero challenged the team to go even further. Rooftop solar panels installed in 2020 now generate 900kWp of peak power — roughly 20% of the facility’s energy needs — which is especially helpful in balancing peak demands during Italy’s sweltering summer months.
“We are proof that, thanks to advancements in energy-efficient technology and digitalization, existing industrial factories can become even more sustainable,” Perani said. “You don’t need to start from scratch to create a model for sustainable, low-carbon operations.”
Smart monitoring, smart savings
At the heart of Dalmine’s energy management is ABB Ability™ Energy and Asset Manager, a digital platform with more than 70 connected devices tracking energy consumption and pinpointing inefficiencies and savings opportunities. Insights enable the team to take simple but impactful steps, such as replacing all traditional outdoor lighting with high-efficiency LED lamps and automating computer shutdowns at night and on weekends. These moves cut energy use by 76,000 kWh annually, enough to power the plant’s growing fleet of fully electric vehicles.
The team targeted Scope 1 emissions by optimizing heating systems and replacing inefficient gas boilers with new energy-efficient generators, reducing the use of methane gas by more than 20%. Temperature settings in meeting rooms and water systems were seasonally adjusted, reducing energy consumption and emissions without compromising comfort.
Circular thinking in action
The site’s dedicated product sustainability team uses life cycle assessments and Environmental Product Declarations (EPDs) to better inform sustainable choices for customers. But the efforts go deeper: Dalmine has cut packaging waste by switching to reusable, recycled plastic crates for transporting components between ABB factories in Europe, cutting nearly a ton of plastic waste annually.
In May 2025, the site achieved Gold-level Zero Waste to Landfill certification from UL Solutions by recycling 99.2% of all on-site waste and sorting waste in production areas and breakrooms. In 2026, the site will target Platinum level certification, recycling or diverting more than 99.5% of all waste from landfills.
Empowering people, inspiring change
Employees are active participants in Dalmine’s Mission to Zero journey. From brainstorming sessions on reducing plastic and paper use to embracing electric vehicles and smart heating and cooling solutions, the initiative has inspired meaningful behavior shifts. Teams are encouraged to share suggestions with management.
“Ideas come from those closest to the process,” said Sabatino Senatore, Dalmine’s facility manager. “When you involve people in actions and initiatives that make a positive impact, you see greater results.”
For example, a cross-functional team created a thermal model of the factory to calculate the annual energy savings of adjusting meeting room temperatures by a single degree.
Quarterly site-wide meetings and initiatives like Health and Safety Week in October 2024, where more than 400 employees explored sustainability challenges, opportunities and best practices, boost engagement and morale. “These efforts help create a sense of ownership and pride,” Senatore said. “Every single person has the power to drive change through everyday behaviors such as reducing water use and eliminating paper through digitization.”
A model for industry
Dalmine’s sustainability journey has continued since becoming a Mission to Zero site. The factory, which achieved ISO 50001 international energy management certification in 2023, recently became the first ABB facility in Italy to fully convert its entire commercial fleet to electric vehicles, supported by 17 EV charging stations.
Sustainable procurement is also a top priority for Dalmine, which is helping create a more sustainable and resource-efficient supply chain by partnering with suppliers to reduce Scope 3 emissions and integrating secondary raw materials into product design and production.
“We see a growing demand for even more sustainable products from our customers, and we demand a similar commitment from our suppliers. Now, we’re focusing not just on factory emissions, but also making partnership and purchasing decisions on secondary impact,” Perani said.
* Compared to 2019 baseline
This is the fourth story in a series about progress made at our first Mission to Zero™ sites around the world. The first site featured was our Porvoo, Finland facility, the second was our Ede site in the Netherlands, and the third featured our inaugural Mission to Zero site in Lüdenscheid, Germany. Mission to Zero is our journey to reach net-zero emissions and more sustainable operations. Bringing together technologies using ABB digital solutions and renewable energy, we’re increasing efficiency and reducing emissions at our sites. To learn more, visit our webpage.
