Manufacturing and production facilities are under growing pressure to maximise their energy utilisation in a time when cost- and sustainability-efficiency are critical. Improving energy efficiency is more than simply cutting costs; it’s also about adhering to strict environmental standards and fulfilling the rising demand for sustainable practices.
Traditional technological solutions include energy management systems, variable speed drives, combined heat and power systems and energy-efficient lighting. However, there are more innovative measure that certain organisations are undertaking to save energy and reduce emissions.
Jaguar Land Rover (JLR) has recently announced plans to generate 120MW of electricity – over a quarter of its UK needs – through on- and near-site renewable energy projects to lower its operational emissions. This initiative is part of JLR’s global renewable strategy, which aims to increase self-generated energy to 36.4% of its global consumption by 2030.
The plan includes using a mix of rooftop and ground-mounted panels, as well as solar carports, tailored to each site to power processes and provide electric car charging at JLR locations. The focus will initially be on key manufacturing and non-production sites in the UK, including the Halewood plant in Merseyside, the newly named Electric Propulsion Manufacturing Centre (EPMC) in Wolverhampton and its Gaydon headquarters. This approach aims to boost self-generated energy capacity from solar by 16%.
Shining examples
The first phase of the strategy is already in progress, with solar projects at Gaydon, Halewood and Wolverhampton expected to increase self-generated energy capacity by 6% by the end of 2026. Planning permission has been granted for an 18.2MW ground-mounted solar array at Gaydon, which, combined with an existing roof-mounted array, will provide around 40% of the facility’s energy needs.
At the EPMC, self-generated solar capacity will increase by 145% through the expansion of existing rooftop arrays, generating 18.9MW and covering 37% of the site’s total consumption. “JLR is committed to managing its net zero energy transition against the challenging backdrop of volatile energy prices,” explains Francois Dossa, JLR strategy and sustainability executive director. “We are working hard as a business to improve our energy efficiency across our entire global operations.
“These new projects will diversify our energy portfolio, to reduce our reliance on grid electricity and help us to reduce our energy bills,” adds Dossa. “The steps we are taking further support our ambitious goal of achieving net zero emissions by 2039 – and to hit our mid-term science-based targets along the way.”
JLR is also piloting a global smart energy metering system at its manufacturing sites and continues to purchase 100% renewable-backed electricity for all core UK operations. Together, these efficiency measures, renewable initiatives, grid decarbonisation and degasification projects will help the company achieve its goal of reducing carbon emissions across its operations by 46% by 2030.
Research published by the BBC last year, based on National Grid figures, indicated that around £200bn worth of solar and wind projects are stuck in a 10-15 year waiting list due to a lack of grid capacity. This underscores why JLR is developing such wide-ranging and innovative energy generation capabilities, to reduce its reliance on the grid.
Guinness net zero
Over in Ireland, alcoholic beverage manufacturer Diageo is investing €100 million in the St James’s Gate brewery in Dublin – where Guinness has been brewed for 264 years – to eliminate fossil fuels and improve water usage on-site. By doing so, Diageo aims to make it one of the most efficient breweries globally by 2030.
The investment will allow St James’s Gate to eliminate fossil fuel use in its brewing operations and reduce Scope 1 and 2 greenhouse gas emissions by over 90%, aligning with the Science Based Target initiative’s net zero definition. By 2030, the brewery’s renewable energy strategy will integrate grid-supplied electrical power, heat pumps, and biogas generated from a new water recovery facility. This facility will enhance water use efficiency, aiming for a 30% reduction in the water that is required to brew Guinness.
“St. James’s Gate is an historic location for an iconic brand. We’re 260 years into our 9,000-year lease at St. James’s Gate,” says Debra Crew, Diageo’s global chief executive officer. “This investment will ensure that Guinness has an exciting and long-term sustainable future. We are proud to lead the way on decarbonisation, both as a major Irish business and as an industry-leading company.”
This initiative is part of Guinness’s broader efforts to future-proof its business. Diageo is committed to reducing carbon emissions across its global operations in line with its 10-year ESG action plan, ‘Society 2030: Spirit of Progress’.
Heat pumps
Meanwhile, Unilever recently updated its Climate Transition Action Plan, highlighting heat pumps as a crucial technology to achieve 100% renewable thermal energy in its factories by 2030. “In our operations, thermal energy use accounts for most of our carbon footprint,” says Vivek Nesarikar, global engineering manager for heating technologies, Unilever. “When we develop decarbonisation roadmaps for our sites, thermal electrification – either through heat pumps, electric boilers or a combination of both – is emerging as a common solution.”
Currently, over a third of Unilever’s thermal energy comes from renewable sources. To meet the 2030 target, Unilever plans to expand the use of heat pumps. “For one unit of electricity consumption, we can get three to four units of useful heat,” explains Nesarikar.
Unilever employs both water source and air source heat pumps. Water source heat pumps recycle waste heat from air compressors, chillers and ammonia systems, while air source heat pumps are used when waste heat sources are not available.
Nesarikar acknowledges challenges with other renewable energy sources: “Green hydrogen is expensive and not viable at scale before 2030, geothermal technology is site-specific and solar thermal is limited by space availability. Heat recovery combined with heat pumps and supported by electric boilers is our preferred technology for uninterrupted heat,” he reasons.
Switching to heat recovery and heat pump technology from steam requires modifications to existing energy distribution networks, which can be complex and costly. However, despite the higher initial cost of heat pumps compared to electric boilers, their lower operating costs make them a favourable investment. Nesarikar suggests using heat demand pattern studies to manage peak loads effectively.
Most processes at Unilever require both heating and cooling, enabling the creation of circular energy in factories by recovering and recycling heat, thus reducing the need for external heat supplies. The percentage of recovered heat varies from 30% to 100% depending on the product category. For example, Home Care detergent towers need air heated to around 400°C, which current heat pumps cannot achieve. In such cases, Unilever relies on sustainable biofuels and continues to seek long-term solutions to the problem.
“We aim to create circular energy in our factories, recovering and recycling heat,” states Nesarikar. “However, for specific high-temperature needs, we ensure our biofuels come from sustainable local sources, aligning with Unilever’s policy on biofuels.”
By harnessing renewable energy, implementing advanced technologies such as heat pumps – and investing in sustainable practices – companies are not only reducing operational costs, but also meeting stringent environmental targets. These efforts highlight the critical importance of energy efficiency in achieving long-term sustainability and setting new industry standards.