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 the 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. The cost-benefit dynamic is clearly shifting in favour of sustainable solutions and partners. After all, energy efficiency and resource conservation are no longer just buzzwords, but measurable factors that directly influence operating costs. Modern automation systems can significantly reduce energy consumption in production and at the same time minimise material waste, for example by using secondary raw materials. These double savings – in energy and material – often leads to faster amortisation of the investment costs than assumed.
But the benefits go far beyond the immediate cost savings. To implement the stricter environmental regulations such as the Energy Efficiency Act (EnEfG) and the CSRD, it is becoming increasingly important to document sustainability performance in a transparent way. Sustainable automation solutions helpcompanies to meet these regulatory requirements. They encourage the creation of energy-efficient processes, improve traceability and provide precise data for sustainability reports.
Sustainable automation can become a catalyst for innovation for both developers and design engineers. Reference data such as energy consumption and carbon footprint are becoming more and more central to the design process. It is crucial to consider both the manufacturing footprint and the lifetime footprint in order to have an overall view. Although the integration of sustainability aspects into the development process requires a rethink, it also offers the opportunity for innovative solutions. By having clear requirements and creating a transparent design using tools, it is possible to integrate the right technology – pneumatic, electric or a combination – with the right size in the system design. The technical possibilities are manifold: With sensors, such as flow sensors in pneumatic systems or torque sensors in electric drives, the energy consumption can be precisely recorded and optimised. Advanced data analysis tools help to optimise machine operation and minimise 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 sustainability balance. Digital twins can provide all the relevant information models for automation components and functional chains as a bundle and as a digital representation, from the engineering process to virtual commissioning (VIBN) and the operating phases through to recycling.
In addition to aspects such as modularity, ease of repair and recyclability, it is beneficial to keep an eye on forthcoming 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, 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. Companiesthat invest in technology at an early stage not only save costs and gain efficiency, but also position themselves as responsible players and reliable partners with stable supply chains in their industry. They are better equipped for future regulatory requirements and can react flexibly to changing market conditions.
The following steps are recommended for the successful implementation of sustainable automation:
1. Carry out a comprehensive energy analysis of your production processes, for example by checking machine running times and current energy consumption
2. Identify the main consumers and potential savings
3. Evaluate automation solutions with a focus on energy efficiency and CO₂ reduction
4. Take PCF (product carbon footprint) values into account when selecting components
5. Integrate sustainability criteria into your supplier selection