The latest virtual roundtable on "Digitalisation for Sustainability" brought together industry leaders to discuss how digital tools are reshaping sustainability efforts in UK manufacturing. With technologies like IoT, AI, and data analytics now more accessible, manufacturers are finding innovative ways to reduce their environmental footprint while boosting operational efficiency.
Thank you to all of the participants for joining in the discussion:
Dan Ireland at Garthwest
Stephen Hall at Advanced Alloy Services
Mike Pennington at Made Smarter
Nick Golding at SWMAS
Tom Harris at Wavenet
Damian Donn at Total Control Pro
Ruth Edwards at Birmingham City University
Nigel Addison-Evans at Control Energy Costs
Here are some of the key insights and takeaways.
Using Data to Optimise Energy Consumption
A major theme from the discussion was the power of real-time data in optimising energy usage. Dan Ireland, Commercial Manager at Garthwest shared how they’ve integrated IoT sensors to monitor energy consumption across their machinery. By analysing this data, Garthwest was able to make operational changes, such as reducing the number of short machine runs and optimising machine use for longer periods. This has not only saved energy but has also reduced their overall carbon footprint, demonstrating the impact of digital tools on day-to-day processes.
Embracing Renewable Energy and Recycling
Stephen Hall, Managing Director at Advanced Alloy Services, emphasised the critical role digitalisation plays in advancing their sustainability efforts. For over 30 years, the company has been recycling superalloys, significantly reducing their need for primary materials. This approach not only lowers the demand for mining but also cuts their overall carbon footprint, making recycling a cornerstone of their sustainability strategy.
In addition to their long-standing recycling practices, Advanced Alloy Services recently worked with FourJaw to install a data monitoring system on-site. Stephen explained that this system tracks energy consumption across various machines, providing real-time insights into their efficiency. "By using this data, we’ve been able to identify where we’re overusing energy and make adjustments that have already led to noticeable savings," he said.
The company has also installed solar panels, which power their operations and charge their new lithium-ion battery forklifts using excess solar energy. As they look ahead, Stephen noted that one of the challenges they face is quantifying their negative carbon footprint to an auditable standard, particularly with the introduction of regulations like the Carbon Border Adjustment Mechanism (CBAM), which will demand greater transparency and accountability across the industry.
Digital Marketing for Sustainability
Interestingly, the conversation also explored how digital transformation extends beyond production processes. Garthwest has shifted its sales and marketing strategy from traditional in-person methods to a predominantly digital model. This has not only reduced their fuel consumption and travel-related emissions but has also resulted in lower costs and improved efficiency. By focusing on online networks, social media, and SEO, Garthwest is seeing growth while actively reducing its environmental impact—showcasing how digitalisation in all areas of a business can contribute to sustainability goals.
Challenges of Integrating Digital Systems
Of course, digital transformation isn’t without its challenges. Many manufacturers struggle with legacy systems that aren’t equipped to communicate with newer, smarter technologies. Nigel Addison-Evans from Control Energy Costs pointed out the issue of disparate systems that fail to integrate smoothly, leading to inefficiencies. Addressing this, participants discussed the importance of IoT solutions that can connect different systems and provide accurate, actionable data.
Cybersecurity in Digital Transformation
Tom Harris from Wavenet raised an important point regarding the cybersecurity risks that come with increased digitalisation. While IoT and AI provide immense benefits in terms of operational efficiency, they also introduce vulnerabilities that manufacturers need to address. Tom emphasised the importance of safeguarding systems and ensuring regular updates to avoid exposing sensitive information. As manufacturers move towards Industry 4.0, keeping cybersecurity at the forefront of any digital strategy will be crucial for long-term success.
Supporting Manufacturers on Their Digital Journey
Mike Pennington from the Made Smarter initiative shared insights from their work with SME manufacturers across North Yorkshire. He noted that many manufacturers are now requesting support for implementing ERP (Enterprise Resource Planning) systems, which help streamline processes and improve data management across departments. This shift shows how manufacturers are realising the value of interconnected systems, allowing them to better track resource usage, enhance efficiency, and make informed decisions that contribute to sustainability.
Bridging the Gap Between Industry and Academia
Approaching the conversation for a different angle, Ruth Edwards from Birmingham City University highlighted the role of academia in supporting businesses on their digital journey. Through knowledge transfer partnerships, BCU works closely with manufacturers to embed new skills and digital capabilities into their operations. Ruth emphasised that digital transformation isn’t a "one-size-fits-all solution"—companies need tailored approaches that can be applied across the business, rather than isolated fixes. This holistic approach helps ensure that digital tools are fully integrated and that sustainability efforts can be maximised.
The roundtable discussion underscored the vast potential for digital tools to revolutionise sustainability in manufacturing. Whether it’s through data-driven energy optimisation, embracing renewable energy, or reducing emissions through digital marketing strategies, manufacturers are proving that technology is not just a tool for efficiency—it’s a key driver for sustainability. With continued investment in digital transformation, the future of UK manufacturing looks both greener and more efficient.