60 tonnes of CO2 saving per year for a high-volume production site
29th May 2025 | 2 min read
The Challenge
The manufacturing industry faces increasing pressure to reduce emissions and improve sustainability. OEMs are accelerating net zero commitments, requiring suppliers to enhance Scope 1 and 2 efficiencies to align with evolving regulatory and environmental expectations.
This challenge explores a structured, data-driven approach to energy optimisation and carbon mitigation in high-volume manufacturing, setting a benchmark for sustainable production practices.
The Solution
As part of the Clean Futures Accelerator Programme funded by the Connected Places Catapult on behalf of the West Midlands Combined Authority, Unipart, in collaboration with Coventry University, has developed a Net-Zero Manufacturing Digital Assistant – a powerful decision-making tool designed to accelerate sustainability in manufacturing.
This tool enables manufacturers to identify, assess, and prioritise carbon reduction strategies for existing production lines, improving energy efficiency and cost competitiveness while supporting net-zero goals.
The team worked closely with Coventry University at our Institute for Advanced Manufacturing and Engineering to deliver innovation and tools to accelerate net-zero initiatives across multiple production sites. The key outcomes included:
- A new bottom-up carbon calculation and mitigation planning tool
- Use of predictive analytics to identify cost-effective decarbonisation solutions
- Implementing a carbon intervention to Unipart’s furnace brazing line, providing auto night-mode functionality, advanced gas mix controls, and flue system upgrades
Measured improvements in energy consumption and costs following installation of Unipart’s energy monitoring system Eco Insight
£100k
cost saving per annum
The Impact
By implementing and testing the tool on Unipart’s furnace brazing line, the following benefits were realised:
- 60 tonnes CO2 saving per year, equivalent to removing almost 40 cars from UK roads annually (equivalent to 3 acres of woodland CO2 capture)
- £100k cost saving per annum
- Improved energy efficiency, reducing waste and operational costs
- Developed an accessible, open-source tool to help manufacturers justify sustainability investments