A Practical Approach to Sustainable Manufacturing

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. This article discusses 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, which leads to significant cost savings for both manufacturers and users.

There are 3 steps that manufacturers should 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; the direct drive motors are lighter, more energy-efficient and require less maintenance than conventional high volume low speed (HVLS) fans. Mitsubishi Electric developed a VFD firmware solution to optimize the performance of these motors. Additionally, they replaced the operator interface with glass touchscreens powered by power over Ethernet (PoE) (Figure 1). This innovation allows flexible placement of controls, reduces the need for separate power infrastructure and facilitates easy reconfiguration and expansion, which leads to lower installation costs and reduced material usage.

2. Right-size components. 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 example, 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 improvement areas. Once the operations were going well, Hunter Fan looked for ways to add new features and functionalities. For example, it 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, users can implement a reporting system for energy usage that can identify areas for improvement and track progress.

Precision reduces failure and material waste

Modern technology offers the ability to produce goods more accurately, which reduces 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.

Balpack, an original equipment manufacturer (OEM) for packaging machinery, collaborated with Mitsubishi Electric and HPE Automation to develop a precise torque control system for capping small bottles (Figure 2). This system boasts unlimited speeds and torque control adjustable to 0.1%, which reduces errors and material waste. As a result, Balpack is helping its customers reduce their carbon footprint.

Recycling instead of disposing

Electronic waste, or 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 more than 75% 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. This emphasizes the urgent need for improved recycling and recovery infrastructure.

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

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, which reduces e-waste significantly. Longer-lasting products require fewer resources—such as raw materials, energy and water—for manufacturing new devices. By extending the lifespan of existing products, the demand for new raw materials decreases, thereby reducing the overall environmental impact.

Yupo, a synthetic paper manufacturer, transitioned from Mitsubishi Electric A Series programmable logic controllers (PLCs) to Q Series PLCs after more than 30 years of reliable use. The forward compatibility of the Q Series with existing automation systems was crucial, which allowed Yupo to upgrade only the PLCs while reusing the input/output (I/O). This approach saved costs, reduced upgrade time and extended the life of existing I/O, which delayed the retirement of the I/O as e-waste. The installation was completed during a brief one-week shutdown, thereby ensuring production resumed smoothly.
 

Final thoughts

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 users to identify and implement practical steps that foster sustainable practices throughout the entire value chain to achieve a circular economy.

Find more Mitsubishi Electric Americas case studies online.

_{This feature originally appeared in the May 2025 edition of Automation.com Monthly.}