Earth’s population will be forced to colonise two planets within 50 years if natural resources continue to be exploited at the current rate, according to a report by the World Wildlife Fund (WWF). In addition, the IPCC special report on the impact of our planet warming estimated that a lift in temperature of just 1.5°C will result in catastrophic effects of climate change. The evidence gives us just 12 years to halt this rise.

The majority of carbon emissions are released by burning fossil fuels to create electricity, heat or motion. Many industrial processes rely on these heating systems to turn raw materials such as oil, iron ore or trees into products such as plastic, metal or food. Consequently, in order to meaningfully reduce greenhouse gas concentrations to prevent life-threatening consequences of climate change, the manufacturing sector must reduce carbon-based energy utilisation. However, this mission results in a real juxtaposition, the wish to strive for industrial growth while monitoring and mitigating the traditional environmental impact of production. Green manufacturing is an emerging industrial trend that could break this paradox, allowing an achievable, long-term approach to manufacturing and industrialisation that addresses environmental challenges systemically. Green manufacturing focuses on altering business and manufacturing practices, as well as the mindset of stakeholders, to mitigate the industrial impact on climate change and other environmental concerns. If applied across the supply chain, and through the customer base, major change could be enacted. The potential of green manufacturing is rooted in the fundamental change towards sustainable practices throughout the entire supply chain of goods. 

 

It is based on a will to ‘do more with less’ and therefore, the manufacturing sector is key to truly invigorating the ‘circular economy’. Traditional manufacturing is linear, as products are made, used, and thrown away. The green manufacturing approach is different as it moves beyond the 3R approach of “reduce, reuse, recycle” toward a 5R approach: “repair, reuse, refurbish, re-manufacture, and recycle”, extending the life of products by maximising the resources used. Whilst this approach is good for the environment, it also has cost benefits for the manufacturer and the end user. For instance, Whirlpool, a global appliance manufacturer, has also adopted enhanced recycling practices in line with the circular economy premise and is on target to realize a three-year saving of $1 million. Key to unlocking the potential of Green Manufacturing is the emergence of the industrial Internet of Things (IIOT) brought about by the Fourth Industrial Revolution. By linking machines together and allowing data to flow throughout the value chain, new opportunities and innovations are made possible. For example, IIoT technology and the development of smart, connected devices, manufacturers can prioritise resource efficiency alongside productivity goals. Connected assets throughout a facility can yield insights into energy use, enabling industrial enterprises to streamline energy and resources from a bottom-line perspective. 

 

Saint-Gobain’s production of high-performance materials, for instance, requires significant amounts of power. Through digital innovation, Saint-Gobain has a realistic goal of curbing energy use and, in turn, cutting carbon emissions by 20% by 2025. The IIOT also creates the opportunity to decarbonize energy across the manufacturing sector. The latest Energy Transitions Commission (ETC) report “Mission Possible” on decarbonising energy sets out a vision to reach net-zero CO2 emissions by 2050. By decarbonizing power and increasing electrification in areas such as transport, the ETC believe that the cost of decarbonisation will be reduced by constraining the demand for carbon-intensive processes. For example, Tesla’s Gigafactory 1 in Nevada is powered by solar energy, harnessing the sunny location to power this mega factory. In addition, Apple has developed a data center that will run entirely on solar upon completion. Partnering with NV Energy, Nevada’s leading utility company, a 200 megawatt solar farm will power what is to become the largest data center in the world. Green manufacturing also suggests a move towards increased utilisation of sustainable materials. This is because if sustainable materials could replace carbon-intensive materials, a major reduction in carbon could be made. For instance, in the buildings sector timber or pozzolan-based concrete could be used in place of Portland cement, whilst biomaterials could replace plastic packaging. 

 

In doing so, if bio materials replaced wheat straw packaging alone, there would be a 40% saving in energy and a 90% reduction in water required for production of the packaging. Yet to ignite this change, consumers need to demand it. One way of inspiring this change is to begin to show consumers how their product is made and how sustainable it is through eco-labelling. Labelling in this way would allow transparency on regulatory compliance, product environmental profiles, and end-of-product-life instructions. Green manufacturing offers revolutionary advances in productivity and efficiency without the downsides of waste or pollution. It allows businesses to thrive and drive efficiency without draining resources or negatively impacting on the environment. Its power, however, depends on the global manufacturing sector embracing a new way of working. One that detaches growth from environmental destruction.