(Source: TakoyakiAI / stock.adobe.com; generated with AI)
Responding to the intensifying pressures of climate change and resource scarcity, today’s companies focus on reducing environmental impact through smarter processes, energy-efficient systems, and artificial intelligence (AI)-enhanced operations. With emerging technologies designed to face modern challenges, Industry 5.0 is positioned to carry on this focus by placing a unique emphasis on sustainability. This blog explores how Industry 5.0 capabilities such as advanced smart automation, Generative AI, and circular economy practices are shaping the future of sustainable industrial processes.
An immediate benefit of Industry 5.0 is the application of advanced automation technologies to reduce energy consumption in industrial environments.
Smart sensors are able to continuously monitor energy usage across equipment such as compressors, heaters, and pumps. The data collected by these sensors are then fed into AI-powered energy management systems, which automatically adjust equipment operations to prevent unnecessary energy use.
For example, when production is low, predictive algorithms can determine the optimal time to turn off or reduce the output of energy-intensive equipment, such as heaters or compressors. This precise control reduces energy consumption and contributes to lower carbon emissions. Moreover, integrating AI into energy management systems means factories can achieve significant savings by ensuring that machines only operate when necessary.
AI’s capabilities also extend to designing more energy-efficient products. AI-driven design tools can suggest product configurations that reduce the need for energy-intensive manufacturing processes, such as welding or soldering. By simply rethinking how parts are assembled, manufacturers can lower their energy consumption and carbon emissions. In these ways, automation technologies reduce energy waste and improve the overall operational efficiency of industrial plants. Furthermore, new products will also be easier to recycle.
AI algorithms can revolutionize how industries manage resources, from raw materials to human capital.
In the context of Industry 5.0, AI is applied to production processes and supply chain optimization. Smart factories now leverage AI to forecast demand, plan inventory, and schedule production more accurately. With an optimized supply chain, companies can reduce material and energy waste.
For example, AI can predict the exact number of materials required for production to minimize overstock and excess waste. It can also consolidate shipments to reduce transportation emissions, particularly when shipping parts or raw materials from overseas. By optimizing shipping routes, AI can ensure that the greenest possible transportation methods are chosen, such as combining multiple shipments into a single container or selecting transportation options with lower carbon footprints.
In addition, AI enables predictive maintenance for better resource optimization. Traditional maintenance schedules often lead to either premature replacements or costly breakdowns. By continuously analyzing data from machines, AI systems can predict when maintenance is truly necessary, which extends the life of equipment and reduces the need for new parts and lubricants, not to mention the excessive use of resources. A well-maintained machine requires fewer repairs, generates less scrap, and uses less oil—all contributing to a more sustainable operation.
The circular economy is a concept that aims to minimize the waste associated with manufacturing. This is achieved generally through two approaches: recycling materials within the manufacturing process and encouraging product take-back programs.
In the first scenario, manufacturers can use industrial automation to recycle heat, water, and materials within the plant, achieving a closed-loop system. For instance, Subaru factories recycle wastewater into pure water for reuse.[1] In other cases, heat generated from industrial ovens can be captured and reused for other processes, such as heating water for facility use.
Product take-back programs are another way automation supports the circular economy. An excellent example is the pump manufacturer Grundfos, which has implemented a take-back program. Through this initiative, customers can return old pumps to the company, where they are either refurbished or recycled.[2] In this context, AI systems can aid in identifying which components can be salvaged and reused in new products.
Many large manufacturers are already integrating solar, wind, and other renewable energy sources into their grid. However, the complexity of managing renewable energy within automated systems presents unique challenges, such as dealing with the intermittency of renewable energy sources.
AI can monitor energy production and storage levels to allow factories to shift between renewable energy sources and the grid as needed. As part of this process, AI can optimize the use of stored energy when renewable sources are unavailable so that operations remain smooth, even when renewable energy production fluctuates.
While the technologies enabling sustainable industrial automation are advancing rapidly, their success depends on effective organizational strategies. All departments within an organization—including engineering, information technology, operations, and supply chain—must be on the same page when implementing new automation systems. However, achieving this alignment often requires significant cultural shifts within companies, as sustainability goals should be prioritized across all levels of the organization.
Once alignment is achieved, the next challenge is integration. New automation technologies must work cohesively with existing infrastructure to maximize their effectiveness. For example, adding robotic systems or smart sensors in one part of the factory should not create isolated pockets of efficiency. Instead, these systems should be integrated into the broader ecosystem to apply energy savings, predictive maintenance, and circular economy practices uniformly across all operations.
Meanwhile, scalability is a concern. As more parts of the operation adopt sustainable automation technologies, the system must grow without losing efficiency. A strong focus on continuous improvement is necessary as new technologies and best practices continue to evolve.
As Industry 5.0 advances, the convergence of automation, AI, and human expertise creates a powerful platform for promoting sustainability. The possibilities for reducing the industrial sector’s environmental impact are vast, from energy-efficient automation technologies to AI-driven resource optimization and the circular economy. However, achieving these goals requires technical innovation and a concerted organizational effort to align, integrate, and scale sustainable practices. Industries adopting these technologies will be better equipped to meet their sustainability goals and build a more resilient and resource-efficient future.
Sources
[1] https://www.subaru.co.jp/en/csr/environment/waterresources.html [2] https://www.grundfos.com/solutions/support/takeback
Hector Barresi is an award-winning Industrial Technology Advisor, Consultant, and Public Speaker specialized in Industrial Automation, Smart Manufacturing, and Digitalization. He has held executive positions at Honeywell, Danaher, IDEX and General Electric, and he is renowned for shaping top-tier Product Innovation organizations globally. Notably, he pioneered the Honeywell XYR5000, the first industrial wireless sensor family on the market, and the groundbreaking Tintelligence smart tinting platform, revolutionizing the paint industry.