Data-driven energy management cuts emissions at ABB’s Sasbach plant

Technology company ABB has announced significant emissions reduction at its Sasbach plant, thanks to on-site renewable energy, electrification and digitalisation.

The Sasbach site manufactures enclosures and energy distribution systems for local and regional markets, and together with 37 other sites worldwide, is participating in ABB’s Mission to Zero programme.

The programme aims to reduce operational emissions across ABBs sites by integrating renewables, energy efficiency measures and smart energy management.

The data-led implementation is delivering results at Sasback, with ABB reporting CO₂ savings of approximately 3,786 tonnes. This includes 2,700 tonnes of CO₂ savings from the purchase of certified renewable electricity from the grid

The site also operates a solar plant which generates 1,500 MWh of electricity annually and saves around 550 tonnes of CO₂ per year. A newly installed transformer station aids with the integration of renewable into the sites existing power infrastructure.

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According to ABB, on-site generation can cover almost one-third of the site’s total electricity demand, providing resilience against volatile energy prices.

Mike Mustapha, President, ABB Electrification’s Smart Buildings Division, commented in a statement: “By investing in on-site renewables, electrifying our processes and using digital energy management, the site is reducing emissions while also improving energy resilience and day-to-day operational stability.

Mustapha continued: “This kind of practical progress is what will matter most for manufacturers navigating the energy transition.”

Energy efficiency measures

ABB has introduced a number of additional initiatives to improve energy efficiency.

LED lights have been installed in production areas, building automation deployed and waste heat recovery from compressed air systems, and optimized process controls

Twenty-one onsite electric vehicle (EV) charging stations have also been made available to support low-emission mobility for employees and visitors.

ABB is continuing to modernise production processes to reduce energy demand and has incorporated heat recovery allowing the facility to operate with lower installed heating capacity than conventional systems.

These measures have been coupled with digitalisation and automation, allowing ABB real-time visibility into energy use and enabling continuous improvement and data-driven decision-making that supports efficiency and resilience.

ABB suggests these results show “how manufacturers can reduce emissions while maintaining reliable, competitive operations.”

This is particularly critical as manufacturing and production account for a large portion of global carbon emissions. Industries need to decarbonise, while continuing to operate optimally in a landscape where maintaining competitive edge is key.

To this end, ABB will continue with its mission at Sasbach, with plans for batter energy storage systems to store excess solar power to meet the needs of peak demand.

The company is also in the process of replacing gas-based heating systems with electric heat-pump solutions, reducing reliance on fossil fuels over time.

In the future, the potential for on-site wind generation will be evaluated.

ABB’s Mission to Zero programme includes a number of locations across Europe, the Americas and Asia. What started as a local initiative at a Lüdenscheid factory in Germany, has grown to yield carbon savings of 60,000 tonnes of CO2e per year across the company’s operations.