ABB’s Green Revolution: Transforming Manufacturing in Brazil

In an era where sustainability is paramount, ABB is spearheading a green revolution at its Belo manufacturing facility in Contagem, southeast Brazil. The company has implemented a series of groundbreaking initiatives that not only slash energy consumption but also significantly reduce carbon emissions. This shift towards energy-efficient manufacturing is a testament to ABB’s unwavering commitment to creating a more sustainable future.

Leading the Charge in Sustainable Manufacturing

ABB’s Belo plant, operational since 1975, has long been a cornerstone in the production of NEMA residential circuit breakers for the Americas. These circuit breakers are critical for safeguarding homes against overcurrent or short-circuit events. Today, this facility is setting a new standard in sustainability, aligning with ABB’s ambitious Mission to Zero™ program.

The Mission to Zero™ initiative is ABB’s pledge to eliminate Scope 1 and Scope 2 greenhouse gas (GHG) emissions by 2050. Through this program, ABB is not only transforming its operations but also empowering customers to optimize, electrify, and decarbonize their businesses.

The Numbers Speak Volumes

The impact of ABB’s sustainability measures at the Belo plant is nothing short of remarkable. In the first year alone, the facility has achieved annual energy savings of 530 MWh and a reduction of 160 tons of CO2e emissions. These impressive results have been driven by several key initiatives:

1. Solar Power Implementation: The installation of solar panels has been a game-changer, generating approximately 220 MWh of renewable energy annually.
2. Energy-Efficient Lighting and Skylights: Upgrading to LED lamps and adding skylights have significantly reduced energy consumption.
3. Advanced Energy Management: The deployment of ABB Ability™ Energy Manager has provided the facility with real-time data to optimize energy usage and identify further savings opportunities.
4. Innovative Frequency Inverters: By integrating energy frequency inverters in high-use production areas, the plant has cut energy consumption by approximately 420 MWh annually.

A Comprehensive Approach to Sustainability

Beyond energy savings and emissions reductions, ABB’s Belo facility is setting a holistic example in sustainable manufacturing. In 2023, the site achieved a CO2e emissions reduction of over 128 tons through green energy purchases. Further reductions of 34 tons were realized by upgrading HVAC equipment and installing enhanced frequency inverters in the molding and stamping areas.

Mike Mustapha, President of ABB Electrification’s Smart Buildings division, underscores the broader impact of these efforts: “The ABB Mission to Zero approach at Belo is another example of our aim to enable a lower-carbon society. Our commitment to accelerating the transition to more sustainable manufacturing is reflected in the significant reductions in energy consumption and CO2e emissions achieved within a year of implementing changes. The highly motivated team at the facility went beyond efficient energy management to ensure that the site delivers zero production waste to landfill by the end of the year.”

Future-Forward Plans for 2024 and Beyond

ABB’s commitment to sustainability is not static; it is a dynamic, ongoing process. The Belo team is already planning further energy savings initiatives for 2024, including:

• Expanding Solar Capacity: Increasing the number of solar panels to meet 30% of the site’s energy demand.
• Enhanced Equipment Efficiency: Installing inverters for compressor and pump machines.
• Electric Vehicle Adoption: Replacing existing forklift vehicles with electric ones.

These forward-thinking plans highlight ABB’s relentless pursuit of innovation and sustainability. The company’s efforts are not just about meeting immediate goals but about laying the groundwork for a more sustainable future.

ABB’s Mission to Zero: A Global Commitment

ABB’s sustainability initiatives at the Belo facility are part of a larger, global strategy. The Mission to Zero™ program is a comprehensive effort to eliminate emissions across all ABB operations worldwide. By leveraging advanced technologies and innovative solutions, ABB is making significant strides toward its 2050 goal.

The implementation of an energy management system according to ISO 50001 is another crucial step in this journey. This system will further drive energy-efficiency actions at the Belo site, ensuring continuous improvement and sustained results.

A Model for Sustainable Manufacturing

ABB’s transformation of its Belo manufacturing facility is a powerful example of what can be achieved with commitment, innovation, and a forward-thinking approach to sustainability. The impressive energy savings and emissions reductions achieved in just one year are a testament to the effectiveness of ABB’s strategies and the dedication of its team.

As ABB continues to expand its sustainability initiatives, the Belo plant stands as a beacon of what is possible. It is a model for other manufacturing facilities worldwide, demonstrating that sustainable manufacturing is not only achievable but also essential for the future of our planet.

For more information about ABB’s Mission to Zero™ program, visit ABB Mission to Zero.

Source: www.abb.com