As a result of a growing awareness of sustainability in all areas of society, the topic of sustainability is also becoming increasingly important for the factories of tomorrow. Although the legitimization continues to vary from sector to sector, the fundamental trend towards the green factory is clearly emerging.
Looking at the entire supply chain, this development is a logical and necessary consequence of a growing market for sustainable products. In addition, compliance requirements and laws are giving the topic increasing momentum. The latest developments relating to the Climate Protection Act, the Energy Efficiency Act, the Supply Chain Act and the CSRD reporting obligation are the most striking examples of the relevant developments.
A Green Factory is characterized by the symbiosis between sustainable processes and a sustainable building. The processes determine the functional and technical user requirements for the building, on the basis of which it is then optimally designed. In operations, the building will later provide the capability for the sustainable handling of all processes in their operational execution.
These interactions require many iterations in the planning process, which we go through together with you as factory and general planners. With the help of the BIM methodology, the resulting complexity can be made manageable and the entire planning process can be managed centrally.
Building or restructuring a green factory requires consideration of economic as well as ecological and social aspects. The result must be an overall system that combines an adequate balance of all aspects, taking into account the individualities present in each case.
Economic aspects in the production environment are usually generated by reducing costs or increasing efficiency. Although the measures associated with a green factory often lead to higher investments (CAPEX) in the short term, they can reduce operating costs (OPEX) in the long term if implemented in a targeted manner. The elimination of waste in the process or an extended flexibility corridor are examples of approaches for which specific measures can be developed.
This aspect centres on reducing the CO2 footprint of your factory. A sustainable building concept (green building) is a significant decision-making lever. In this context, the integration of solutions for renewable energy generation is only the most obvious application from a wide range of possibilities. On request, we can accompany you on the way to the desired certification, for example according to DGNB or LEED standards.
However, process-based approaches can also be used to realize further potential that is not mapped via the building. Relevant competitive advantages can be achieved with sustainable processes. Together, we determine how your CO2 footprint can be reduced through intelligent production planning and control or through the use of alternative technologies in production and logistics.
The third aspect is still often primarily associated with ergonomic workstation design. However, the topic as a whole covers a broader field with growing design options thanks to many developments. Increasing automation is increasingly focussing on the topic of "human-technology interaction", which opens up new scope for action, for example. Furthermore, we still often encounter attractively designed office environments as opposed to outdated shop floor environments. This transfers an ambivalent demeanor both internally and externally. In the increasing competition for qualified specialists, this does not make the company more attractive as an employer. Together, we will align your production environment for the future and close any discrepancies.
The goal of setting up a green factory or reorganizing an existing factory accordingly requires a great deal of diversity of perspective. Consequently, a solution space must be considered that extends beyond the company's own boundaries. The establishment of "energy clusters" is becoming increasingly important if ambitious demands such as energy self-sufficiency etc. continue to materialize.
In this context, the focus is shifted from the individual consideration to the system network, for example by passing on surplus energy potential within an energy network. Enabling infrastructure (e.g. stationary energy storage systems) is required for these interactions, the design of which must be taken into account as part of factory planning.
In terms of sustainability, it must be emphasized that all decision recommendations must be based on a comprehensible derivation. From a business perspective, this means that all measures identified to implement ecological and social aspects must always be in an appropriate relationship to economic considerations. These interrelationships are part of a business case that is ready for a decision and forms the basis for a Green Factory.
What is stopping factory operators from focusing even more strongly on sustainability?
Surveys show that the cost-benefit factor in relation to sustainability is not considered attractive enough by many factory operators. In addition, the bureaucratic hurdles pose organizational and capacity challenges, especially for SMEs. With objective assessments, we work with you to find the right balance of economic, ecological and social aspects for the design of your factory.
How do process and building interact in a Green Factory?
The optimal interplay of sustainable processes and an enabling building structure forms the foundation of a green factory. The decision in favor of a sustainable alternative compared to a conventional solution generally always requires a process-related and structural perspective. For example, process operation using sustainable energy sources requires infrastructural prerequisites (e.g. stationary energy storage) in order to decouple the time of energy generation from energy use. As a result, factory and building planning must work closely together at an early stage in order to develop feasible solutions.
Business Development Manager
Managing Partner
Theresa Hönicke // Manager - Factory Planning