Sustainable Manufacturing: A Practical Approach to Responsible and Efficient Production

Summary

The need for sustainable manufacturing practices is more urgent than ever. Businesses are motivated by cost savings and environmental concerns to make their processes more responsible. Let's discuss practical strategies for manufacturers to achieve sustainability, starting with their own production and extending to their end users. By doing so, the entire supply chain—from suppliers to manufacturers to end users—can collectively meet financial, environmental and social responsibilities.

Efficient and sustainable manufacturing

Modern industrial automation products are designed to optimize energy usage throughout the manufacturing process. This results in energy savings during the asset's lifecycle and enhances resource efficiency and longevity, leading to significant cost savings for the manufacturers and end users alike.

Here are three steps that manufacturers could follow when designing their equipment to get started on this journey:

1. Adopt modern technology

Hunter Fan adopted modern technology to enhance sustainability by using direct drive motors in their industrial fans, which are lighter, more energy-efficient, and require less maintenance than conventional HVLS fans. Mitsubishi Electric developed a VFD firmware solution to optimize these motors' performance. Additionally, they replaced the operator interface with glass touchscreens powered by Power over Ethernet (PoE). This innovation allows for flexible placement of controls, reduces the need for separate power infrastructure, and facilitates easy reconfiguration and expansion, leading to lower installation costs and reduced material usage.

2. Right-size components challenge the one-size-fits-all mentality

Hunter Fan's shift from a one-size-fits-all approach to right-sizing components highlights the sustainability benefits of customization. By tailoring solutions to meet specific customer needs, they avoid the inefficiencies and unnecessary energy consumption associated with oversized components. This approach not only reduces utility bills but also enhances overall efficiency. For instance, at an airport, installing Hunter HVLS fans led to nearly 30% energy savings, demonstrating the cost-effectiveness and environmental benefits of using appropriately sized components in large spaces.

3. Use data to identify more areas for improvement

Once the operations were going well, Hunter Fan looked for ways to add new features and functionalities. For instance, they wanted to group fans together and power them on and off instead of individually. They also wanted to be able to control the fans through various building automation systems so they could program on and off times and vary fan speeds based on current temperatures. Once connected to a building system, end users can implement a reporting system for energy usage that may identify areas for improvement and track progress.

 
Precision means less failure and less material waste

Modern technology offers the ability to produce more accurately, reducing material waste without compromising throughput. Manufacturers can strive for higher precision in their machine controls to operate in line with today’s sustainability standards and showcase a commitment to environmental responsibility.

Reducing Carbon Footprint with components built for precision: Balpack Case Study

Balpack, an OEM for packaging machinery, collaborated with Mitsubishi Electric and HPE Automation to develop a precise torque control system for capping small bottles. This system offers unlimited speeds and torque control that is adjustable to one-tenth of a percent, significantly reducing errors and material waste. Through the collaboration, Balpack was able to get very precise torque control that reduces failures and, in turn, material waste. As a result, Balpack is helping their end customer reduce their carbon footprint. 
 

Stop the “throw-away” disposable mentality in manufacturing

Electronic waste (e-waste) has become one of the fastest-growing waste streams in the world. In 2022, approximately 62 million metric tons of e-waste were generated globally, nearly doubling since 2010. Despite this growth, waste management remains inadequate, with over three-quarters of e-waste still going undocumented. By 2030, the global total is expected to exceed 80 million metric tons. The growing consumption of electronic products with shorter life cycles and fewer repair options drives this rapid increase. Only 17.4% of e-waste is properly collected, treated and recycled, highlighting the urgent need for improved recycling and recovery infrastructure.
 

When it comes to quality, do not settle.

Investing in quality components ensures longer product lifespans and reduces the need for frequent repairs and replacements, thereby minimizing electronic waste and the environmental impact of manufacturing new components. While replacing failed components without troubleshooting is common, especially in critical applications, manufacturers should prioritize durable products. Most electronic components are designed to last 10 years, so frequent premature failures should prompt an investigation into the root cause to reduce e-waste. Manufacturing equipment should meet the promised quality and value rather than be disposable.
 

Benefits of forward compatibility and longer useful life

Forward compatibility enables businesses to integrate new technologies with legacy systems incrementally, enhancing old equipment without needing simultaneous upgrades. This approach extends the value of reliable equipment, significantly reducing e-waste. Longer-lasting products require fewer resources for manufacturing new devices, such as raw materials, energy, and water. By extending the lifespan of existing products, the demand for new raw materials decreases, thereby reducing the overall environmental impact.
 

Case Study: Yupo

Yupo, a synthetic paper manufacturer, transitioned from Mitsubishi Electric A Series PLCs to Q Series PLCs after over 30 years of reliable use. The seamless forward compatibility of the Q Series with existing automation systems was crucial, allowing Yupo to upgrade only the PLCs while reusing the I/O. This approach saved costs, reduced upgrade time, and extended the life of existing I/Os, delaying their retirement as e-waste. The installation was completed during a brief, one-week shutdown, ensuring production resumed smoothly.
 

Conclusion

Sustainable manufacturing transcends mere environmental responsibility; it embodies the essence of making financially prudent decisions that benefit both the business and the broader community. It necessitates a collaborative effort among manufacturers, machine makers, and end users to identify and implement practical steps that foster sustainable practices throughout the entire value chain to achieve a circular economy.