The integration of Industrial Automation and Renewable Energy in Indian factories is not just an environmental imperative but also a strategic necessity.

The Indian Industrial landscape is going through a monumental transformation as the world moves towards a sustainable future. Green factories, powered by automation and renewable energy, are emerging as a cornerstone of this transition. These eco-friendly manufacturing facilities are not only reducing the environmental footprint but also increasing operational efficiency. As India aims to become a global manufacturing hub under initiatives like ‘Make in India’, the integration of green technologies into factories is imperative for long-term growth.

Understanding green factories

Green factories are entities leveraging a mix of sustainable practices and technologies to minimise energy consumption, reduce waste, and optimise resource utilisation. These factories integrate renewable energy sources like solar, wind, and biomass with advanced automation technologies such as industrial automation, artificial intelligence (AI), and the Industrial Internet of Things (IIoT) to not only enhance their efficiencies, but have a positive impact on the environment. The result is a self-sustaining ecosystem that aligns economic growth with environmental stewardship.

If we take it in the Indian context, then this green factory movement aligns perfectly with the nation’s commitment to achieving net-zero emissions by 2070 and transitioning to 50% renewable energy sources by 2030. With a rapidly growing industrial base and an increasing focus on sustainability, green factories are set to play a pivotal role in shaping India’s industrial future.

The role of automation in green factories

Industrial Automation is the backbone of green factories, enabling improved efficacy and accuracy. Advanced technologies such as AI, IIoT, and other new technologies allow factories to optimise energy usage, monitor resource consumption, and also help predict maintenance needs thereby enabling the factories to enhance their efficiency and productivity. Adoption of Industrial Automation have several benefits which the factories can leverage upon to embrace on the ride to sustainability and efficiency:

1. Energy Optimisation: Industrial Automated equipped systems can monitor and control energy consumption in real time by predicting peak energy demands and adjusting operations accordingly there by enabling the factories to take real time informed decisions to reduce energy bills and have a relatively smaller carbon footprint.

2. Waste Reduction: Industrially automated and equipped facilities actuate the defined manufacturing processes, which helps in reduction of material waste. Once the systems start functioning in the defined process, equipped with sensors throwing real time information and controlling any thing which goes haywire than the defined processes, the resultant is that of unmatched accuracy, ensuring minimal errors and rework.

3. Predictive Maintenance: IIoT-enabled devices have the capacity to monitor the health of machinery and predict failures before they occur. This minimises downtime, extends equipment lifespan, and reduces waste generated by unexpected breakdowns.

Renewable energy integration: Powering the future

For a factory to be truly green, one of the major focuses is having a positive impact on the environment and renewable energy is at the heart of that, enabling them to operate with minimal reliance on fossil fuels. India has an abundance of solar and wind resources, which uniquely positions it to lead this transformation. The integration of renewable energy into factory operations can be achieved through the following measures:

1. Solar Power: India’s geographic positioning offers immense potential to garner solar energy for its domestic as well as industrial requirements. Installation of rooftop solar panels or establishing solar farms to generate power are the ways to generate energy from solar. This when done by the factories themselves, enables them to either be self sufficient or very less reliant on outside power supplies which are basically fossil based and hence reducing their carbon footprint to greater extent. Also, if these are integrated with the Industrial Automation technologies, it can lead to greater efficiency in energy production. For instance, companies in the States of Gujarat and Rajasthan are already leveraging solar energy to meet a significant portion of their energy needs.

2. Wind Energy: Wind farms in states like Tamil Nadu and Maharashtra are producing a commendable amount of power and can supply factories with clean electricity. By integrating wind energy into their power grids, factories can reduce their dependence on conventional energy sources.

3. Biomass Energy: India’s agricultural sector generates a substantial amount of biomass, which can be converted into energy if leveraged in a proper manner. States like Maharashtra, Andhra Pradesh, Karnataka and a few others have already started their pilots for leveraging this renewable source to meet the energy needs. Factories in rural areas can use this renewable resource to meet their energy needs which will not only help the environment, but also become a new source of employment in those areas.

4. Energy Storage Systems: To ensure a consistent energy supply, green factories are adopting advanced battery storage solutions. These systems store surplus energy generated during peak production periods and release it during off-peak times.

Government initiatives and policies

Indian government, understanding the impact of environmental corrosion, and importance of energy for industries and factories, is playing a proactive and vital role in promoting green factories and move towards clean energy through various initiatives:

1. Production-Linked Incentive (PLI) Schemes: The government’s PLI schemes for sectors like electronics, automobiles, and textiles encourage the adoption of green technologies by providing financial incentives.

2. National Solar Mission: This mission aims to achieve 280 GW of solar capacity by 2030, enabling industries to tap into affordable and clean energy. This is not only helping the government to reach their goal of net zero carbon emission, but also is enabling them to generate a good amount of employment there by strengthening the economy further.

3. Energy Efficiency Financing Platform (EEFP): The EEFP facilitates access to financing for energy-efficient projects, helping industries transition to green practices.

4. Tax Incentives: Tax benefits for investments in renewable energy and automation technologies encourage businesses to adopt sustainable practices.

The economic and environmental impact

The adoption of green factories has far-reaching economic and environmental implications for India:

1. Job Creation: The transition to green factories helps in creating new employment opportunities in areas such as renewable energy installation, automation, and maintenance.

2. Enhanced Competitiveness: Green factories help in reducing operational costs and improve efficiency, making Indian products more competitive in the global market.

3. Reduced Carbon Emissions: By shifting to renewable energy and automation, factories end up significantly lowering their carbon footprint, contributing to India’s climate goals and having a positive impact on the environment.

4. Resource Conservation: Optimised processes and reduced waste contribute to the conservation of natural resources, ensuring long-term sustainability.

The road ahead: A sustainable vision

The future of green factories in India lies in a collaborative approach involving the government, private sector, and academia. Here’s how India can accelerate the adoption of green factories:

1. Public-Private Partnerships (PPPs): Collaboration between the government and private sector can drive investments in green technologies and infrastructure. This has already begun in a few arenas, but a larger adaptability looking at the requirements of the Indian economy is required at a faster pace.

2. Skill Development Programs: Initiatives to upskill the workforce in areas such as Industrial Automation and Renewable Energy are crucial for building a robust talent pool. This helps in easier adoption and implementation of Greener Factories, thereby having a positive impact at a much faster pace.

3. Incentivising Innovation: Encouraging research and development in the field of green technologies can lead to affordable and scalable solutions tailored for Indian industries.

4. Awareness Campaigns: Awareness regarding the long-term benefits of green factories is required, which is poised to drive adoption, particularly among the SMEs who are now the backbone of the Indian economy.

5. Strengthening Policy Frameworks: Though the Government has now taken positive steps in encouraging the industries, further more comprehensive policies and incentives are required to support the transition to green factories, ensuring alignment with national and global sustainability goals.

Conclusion

The integration of Industrial Automation and Renewable Energy in Indian factories is not just an environmental imperative but also a strategic necessity for economic growth. Green factories represent the future of manufacturing, offering a pathway to sustainable growth and industrialisation. By embracing this vision, as India inspires to be a global manufacturing leader, it could contribute by showing a more sustainable way of manufacturing, contributing to a cleaner, greener, and a more prosperous world.

For additional insights, please contact: Ashwini Singh, AGM – Sales & Marketing, Rexel. Cell: +91-7888025310. Email: [email protected]