Rising energy costs and the need to reduce CO2 emissions pose major challenges for companies. Strict regulations such as the CSRD (Corporate Sustainability Reporting Directive) and the implementation of new standards such as Science Based Targets (SBTi) require increased effort from companies. At the same time, customers now have high expectations of their suppliers in terms of product carbon footprint (PCF), environmentally friendly and sustainable materials and energy efficiency.
For purchasers and decision-makers, this opens up a new perspective on investments in automation technology. Energy and material costs may influence the economic viability of efficient automation solutions. After all, energy efficiency and resource conservation are no longer just buzzwords, but measurable factors that directly influence operating costs. Depending on the baseline system, efficiency measures may reduce energy consumption and operating costs; payback periods must be calculated for the specific application. These double savings – in energy and material – often lead to faster amortization of the investment costs than assumed.
But the benefits go far beyond the immediate cost savings. To implement stricter environmental regulations such as the Energy Efficiency Act (EnEfG) and the CSRD, it is becoming increasingly important to document sustainability performance transparently. Selected automation and data solutions may provide technical data for energy and sustainability management. They encourage the creation of energy-efficient processes, improve traceability and provide precise data for sustainability reports.
For developers and designers, sustainable automation can become a catalyst for innovation. Key figures such as energy consumption and carbon footprint are becoming the focus of the design process. For a holistic view, it is important to consider both the manufacturing footprint and the lifetime footprint. Integrating sustainability aspects into the development process requires a rethink, but at the same time offers the opportunity for innovative solutions. Clear requirements and transparent configuration with the help of tools help to use the right technology – pneumatic or electrical or combined solutions – with the right dimensions in the system design. The technical possibilities are manifold: Sensors, such as flow sensors in pneumatic systems or torque sensors in electric drives, enable precise recording and optimization of energy consumption. Advanced data analysis tools help to optimize the operation of machines and minimize the consumption of resources. Condition monitoring systems can predict and prevent failures, which not only increases system efficiency but also extends the service life of components. Products with a reduced carbon footprint (such as those made from organic polymers) also contribute to an improved overall balance. Digital twins can provide all relevant information models for automation components and effect chains, combined and as a digital representation, from the engineering process to virtual commissioning (VCOM) and the operating phases through to recycling.
In addition to aspects such as modularity, easy repairability, and recyclability, it is advantageous to keep an eye on future developments when developing future-proof automation solutions. The EU's planned digital product passport is an example of future regulations that should already be included in design decisions today. It contains detailed information about a product, such as its carbon footprint, for example, and is intended to improve transparency along the entire value chain.
Sustainable automation is more than just a trend, because in an increasingly environmentally conscious world, it can make a decisive contribution to the long-term success of a company. Depending on the application and baseline, investments in energy- or resource-efficient technology may offer savings potential. They are better equipped for future regulatory requirements and can react flexibly to changing market conditions.
The following steps are recommended to successfully implement sustainable automation:
1. Carrying out a comprehensive energy analysis of your production processes, for example by checking machine running times and current energy consumption
2. Identification of main consumers and potential savings
3. Evaluation of automation solutions with a focus on energy efficiency and reducing carbon footprint
4. Consideration of PCF (Product Carbon Footprint) values when selecting components
5. Integration of sustainability criteria in your supplier selection