Decarbonizing Manufacturing:
Pathways to a Sustainable Future
Haven’t we all blamed the sun, for the sweltering heat and the blazing hot tar roads at least once in our lives?
Aren’t we all guilty at the back of our minds, regarding the amount of carbon we are emitting per day that has skyrocketed global warming in the past few years?
Did you know that the Earth was about 2.45 degrees Fahrenheit (or about 1.36 degrees Celsius) warmer in 2023 than in the late 19th century (1850-1900). Unfortunately, scientific consensus like these overwhelmingly agrees that human activities, primarily burning fossil fuels, are the primary drivers of recent global warming. Even though we cannot let our individual carbon footprints go unnoticed, think about the amount of carbon that is emitted throughout the globe per day! Horrifying isn’t it?
If I say that today’s global economy is thriving thanks to the manufacturing industry, you would certainly agree! And it’s true! Even though manufacturing is the driving force of our current economy, it is a major contribution to global carbon emissions. From the extraction of raw materials to the production and transportation of goods, every step in the manufacturing process leaves an environmental footprint. Factories have huge energy demands that meet burning fossil fuels, releasing harmful greenhouse gasses into the atmosphere.
Therefore, decarbonizing the manufacturing sector is not merely a moral imperative but also a strategic necessity in the face of climate change. By embracing innovative technologies, sustainable practices, and collaborative partnerships, manufacturers can chart a course towards a low-carbon future while simultaneously enhancing operational resilience and competitiveness. It is our responsibility to create and continue initiatives regarding the journey towards decarbonization, offering practical solutions to reduce emissions and build a sustainable manufacturing ecosystem.
Decarbonization at a glance!
Decarbonization is the process of significantly reducing or eliminating carbon dioxide and other greenhouse gas (GHG) emissions caused by human activity, which contribute to global warming and other hazardous events that destabilize our environment.The pathway to decarbonization can vary sector by sector due to the differences in processes and materials in different industries.
Businesses have a critical role to play in driving sustainability efforts forward. One key way they can contribute is by aligning with the Science Based Targets initiative (SBTi). That is an initiative with a strong target to reduce global carbon emissions by 1.5° by 2030 in line with the Paris Agreement’s goal. Science Based targets set by the SBTi are a set of goals and agreements in favor of companies that have a strong will to enhance their sustainability standards.
In addition to SBTi, ESG (Environmental, Social, and Governance) reporting is another essential tool for businesses looking to improve their sustainability standards which is a type of corporate disclosure that covers an organization's work, efforts, risks and promises under 3 key sections: Environmental, Social and Governance. Finally, GHG (Greenhouse Gas) reporting is the process of documenting the amount of GHGs such as Co2, CH4, CO etc. emitted by a business, organization or country. By measuring their emissions, companies can set concrete targets for reduction and contribute to global decarbonization efforts.
Now you might wonder why science based targets and ESG reports are crucial for businesses?
Did you know that ESG reporting is now legally required in over 40 countries, including the UK, several EU nations, North America, Australia, Japan, and soon South Africa. Therefore, ESG is a non- negotiable for all the exporters.
Rules, regulations and reports are just the cherry on top. Let’s talk about the groundwork the manufacturing industry can execute for a much more sustainable future. The effect of technology is also at the forefront when it comes to decarbonizing the manufacturing industry.
Modern day technology’s contribution for decarbonizing manufacturing.-
Automation and robotics
Automated systems and robotics are wired to perform 24/7 with lower energy costs at an optimum efficiency and accuracy that will eventually lead to drastically reduced material and energy wastage. This has the potential to streamline supply chains by optimizing production and logistics in favor of less transportation and storage energy use. Automation can also be integrated with IIoT systems to monitor equipment in real time, predicting when maintenance is needed.
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Industrial of things (IIoT)
The use of smart sensors, actuators and other devices such as radio frequency identification tags in a network, can predict when machines will require maintenance, preventing breakdowns, and ensuring that equipment runs efficiently, reducing unnecessary energy use and emissions.
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3D Printing
3D printing involves building an object or pattern layer by layer, using materials to create the final shape, unlike subtractive manufacturing, where a design is carved from a larger block of material. Advanced 3D printing technologies can use recycled or biodegradable materials, which help lower carbon emissions compared to conventional textiles that require intensive raw material extraction and processing.
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Extended Reality (XR)
All common forms of XR (Augmented reality(AR), Virtual reality(VR) and Mixed reality(MR) ) allow testing of virtual prototypes before creating physical prototypes. XR can train employees in virtual environments without needing physical equipment or locations. XR can facilitate the creation of digital twins—virtual replicas of physical systems—allowing for real-time monitoring, optimization, and predictive maintenance of manufacturing processes.
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Renewable energy
The use of renewable energy such as solar and wind power will dramatically contribute to decarbonization as there is zero greenhouse gas emissions. Apparel factories powered by renewable energy often invest in energy-efficient technologies, further reducing energy consumption and improving operational sustainability.
Decarbonizing the Apparel Manufacturing Industry
Fast fashion has a devastating impact on our planet, driven by the neverending consumption and a focus on low-cost disposable clothing. The industry's thirst for cheap materials fuels unsustainable agricultural practices, such as excessive water use for cotton cultivation and deforestation for the production of viscose, a common textile derived from wood pulp. The dyeing and treatment of fabrics often involve toxic chemicals polluting waterways and posing risks to workers and communities.
The transportation of garments around the globe, often by air, further adds to the industry's carbon footprint. One major crisis in the apparel industry is that wastage consistently exceeds production. Landfills overflow with discarded garments that take decades, if not centuries, to decompose. Did you know that since 2000, the amount of clothing manufactured annually has doubled, reaching over 100 billion for the first time in 2014, according to studies that is nearly 14 pieces of clothing for each person on the planet.
It is quite shocking to say that within 92 million tons of garments that are dumped into landfills annually worldwide, only less than 15% are recycled. Meanwhile, the rest, results in burning of textiles releasing an abundance of carbon dioxide into the environment.
Not only that, if not handled efficiently and accurately, employee transportation services offered to operators of garment factories have such a huge impact on the carbon footprint of the apparel industry than it should be.
If we think outside the box, solutions to any problem are within reach. Now, let's examine ways to revolutionize the apparel manufacturing industry for a greener tomorrow.
Means for a greener Apparel Manufacturing Industry-
Sustainable materials
Switching to more sustainable materials such as organic cotton, organic wool, hemp, bamboo, recycled polyester, Econyl and many more, aids to the reduction of the carbon footprint of textile production. How these sustainable materials contribute to decarbonization is surely fascinating. Hemp grows quickly and absorbs carbon dioxide from the atmosphere during its growth, making it a carbon sink. Bamboo also acts as a carbon sink, absorbing significant amounts of CO2 during growth while organic cotton reduces soil degradation and carbon emissions from synthetic fertilizers and pesticides.
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Digital solutions
Digital solutions often aid factories and companies to go either paperless or reduce their usage of paper and other materials for tasks such as prototypes, tremendously. It has been studied that streamlined technology usage can drastically reduce the carbon footprint associated with travel and physical samples of a factory.
Here are a few of the digital solutions the apparel manufacturing industry have been using for the past few years.- 3D Printing
- Augmented Reality (AR) and Virtual Reality (VR)
- Digital Twins
- Robotics and AI driven automations
- Digital Printing
- Artificial Intelligence (AI)
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Waterless dyeing
Conventional dyeing techniques demand a substantial amount of water and can lead to water pollution. Waterless dyeing technologies, like air dyeing, can significantly lower the water usage and carbon emissions involved in the textile manufacturing process.
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Renewable energy
Factories and manufacturing processes switching to more renewable energy sources such as solar power and wind power will reduce the apparel industry’s carbon emissions by a considerable amount.
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Sustainable packaging
The industry can switch to sustainable packaging materials, such as biodegradable or compostable packaging, to reduce the carbon footprint of product packaging and disposal.
Decarbonizing the transport sector
Did you know that the transportation sector—which includes all modes of travel through land, air, and sea to move people and goods account for one-quarter of global GHG emissions? Without immediate action, its share could reach upto 40% by 2030. Over the past 50 years, transport emissions have increased more rapidly than those of any other sector. Since the demand for transport will continue to grow massively in the coming decades, the CO2 emissions from transport activity will definitely not fall, but could increase by 60% by 2050.
Buses and trucks, which often operate on diesel, emit large quantities of CO2 and other pollutants, impacting air quality and exacerbating global warming. Similarly, personal vehicles, despite advancements in fuel efficiency, continue to be a major source of carbon emissions. Collectively, all these vehicles are a major driver of increased carbon emissions, making their transition to cleaner, more sustainable energy sources crucial for meeting climate goals and reducing the environmental impact of transportation.
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Ways to cut carbon emission in the transport sector.
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Electrification(EVs)
One way we can cut down on CO2 emissions drastically is by transitioning from fossil fuel-powered cars, trucks, and buses to electric alternatives. This shift requires expanding charging infrastructure and investing in advanced battery technologies to make EVs more accessible and practical for everyday use. Electric vehicles are approximately 40% cheaper than non-electric vehicles. But when vehicles get fully autonomous (self-drive), the estimate is that it will be 10 times cheaper than a conventional vehicle.
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Enhancing public transportation systems
Expanding and improving the efficiency of buses, trains, and metro services can reduce the number of individual car journeys. Electrifying these transit fleets and optimizing routes to make public transit more convenient can encourage more people to use these services instead of personal vehicles.
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Promoting active transportation modes
Promoting active transportation modes, such as cycling and walking, can significantly reduce reliance on cars. Building bike lanes, pedestrian pathways, and ensuring safety measures for these modes can make them more attractive alternatives.
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Integrating renewable energy sources and Investing in alternative fuels and technologies
Ensuring the electricity used to charge EVs comes from renewable sources like wind, solar, and hydro power can further decrease the sector’s carbon footprint. Additionally, developing and using renewable fuels, such as biofuels made from organic materials, can reduce reliance on fossil fuels in existing internal combustion engines. Alternative fuels such as hydrogen fuel cells for heavy-duty vehicles and advanced biofuels, provides additional avenues for reducing emissions. Improving vehicle efficiency through stricter fuel economy standards and regular maintenance can also contribute to lower emissions.
Decarbonizing our manufacturing industries and the transport sector is not just an option but a necessity for ensuring a sustainable and greener future. We must all take responsibility for reducing our carbon footprint and mitigating climate change. KingslakeBlue is committed to this vital journey and offers innovative solutions to support these efforts. Our KingslakeBlue Transport Management System (TMS), KingslakeBlue Line Balancing and KingslakeBlue Cutting Plan are specifically designed to enhance efficiency, reduce emissions, and contribute significantly to the decarbonization of the transport sector. By leveraging these advanced tools, we can drive meaningful progress toward a more sustainable and eco-friendly industry, aligning with our collective goal of a greener planet.
