Green Manufacturing: How Material Innovation Drives Sustainability
By Jack Shaw
Traditional manufacturing processes often take a toll on the planet, contributing to depleting natural resources and increasing pollution. Fortunately, there’s a way manufacturers can be a force for good.
Green manufacturing via material innovation can help build something efficient and kinder to the environment. Discover how it can drive sustainability and explore strategies you can use in your organization.
What Is Green Manufacturing?
Green manufacturing is about producing items that cause little to no environmental harm. It honors the 5R approach — repair, reuse, refurbish, rebuild and recycle. Companies can practice green manufacturing through reducing waste and pollution, adopting energy-efficient technologies and following circular economy principles.
The Role of Material Innovation
The built environment accounts for about 42% of global emissions yearly. The planet is warming, and climate change is palpable across the world. This significant number is a call for ways to innovate materials more sustainably. Here’s how it’s making a difference to the planet.
Reduces Resource Depletion
Environmental resources are finite, and global consumption patterns are alarming. Innovation involves using materials more efficiently and reducing waste. Moreover, material innovation explores resources that can be replenished naturally and provide durability.
Minimizes Waste and Pollution
According to experts, 2023 saw 66 million tons of atmospheric pollution. This alarming number calls for innovations that help promote a better environment for today and tomorrow. Creations that replace hazardous substances with safer options can help reduce pollution and its health risks.
Improves Manufacturing Techniques
Material innovations can go hand in hand with operations that require less energy. For instance, 3D printing can help design lightweight parts and consolidate components to reduce costs, weight and energy consumption. It lets you create complex designs with ease, leading to a more efficient production process.
Examples of Sustainable Material Innovations
Material innovation is constantly evolving, and there are many options professionals can explore for green manufacturing. Here are some examples across different industries.
Bio-Based Polymers
Bio-based polymers are derived from renewable sources like corn starch or sugarcane. They are sustainable polymers that help reduce fossil fuel consumption and plastic pollution due to their high biodegradability.
Rice Husks
Rice husks — or the protective outer layers of rice grains — can be a promising organo-mineral raw material. They contain cellulose and lignin, which can be used to create things like paper, bioplastics and even biofuels. What was once considered waste can be transformed into various eco-friendly products.
Recycled Aluminum
Recycling aluminum saves 95% of the energy needed for primary production, helping reduce direct and indirect emissions. Using this material for your innovations can help the environment and the economy, leading to lower carbon footprints.
Organic Textiles
Organic cotton, linen and hemp offer a more eco-friendly alternative to conventionally grown textiles. Farmers grow them without synthetic toxic pesticides and fertilizers, which can contribute to pollution, harm biodiversity and cause health risks to manufacturers and consumers.
Many companies are certified to traceability standards like the Textile Exchange Organic Content Standard, which confirms that the final product is certified organic.
5 Steps Manufacturers Can Implement to Become Greener
There are many impactful ideas you can put into action. Discover some ideas you can apply to your company’s manufacturing processes.
Use Ultra-Precision Machining
Ultra-precision machining helps minimize material waste through highly accurate shaping and cutting abilities. Advanced high-speed CNC equipment can deliver ultra-precision machining for various components, such as titanium, stainless steel, steel alloys, polypropylene and Styrene. Such process improvements can improve the durability and performance of raw materials.
Assess Materials Properties and Performance
Material properties like strength, density, stiffness, biodegradability, and thermal conductivity can impact the environment. For example, choosing lightweight materials can help reduce vehicle emissions and increase energy savings.
Implement Waste Reduction Activities
Waste reduction strategies help cultivate a culture of reusing and recycling in your company. Find ways to reduce water consumption and treat wastewater effectively before discharge.
You can also optimize material use and implement closed-loop recycling systems to reduce landfill waste. Instead of discarding used materials, explore opportunities to remanufacture them into new condition or refurbish them for resale to minimize the need for initial production.
Create Better Product Designs
Design materials that require fewer materials but offer the same functionality. Hollow structures, optimized shapes and other compatible materials allow for disassembly and reassembly, which makes for easier reuse.
These designs can help promote a “repair, don’t replace” culture, which can positively impact the environment. Work with other suppliers to ensure sustainability is applied throughout the supply chain.
Educate Your Team
Empowering your workmates can help everyone contribute to a greener future for the organization.
Explain why sustainable material innovation matters and its environmental benefits via training sessions and workshops. You could hire someone knowledgeable about green manufacturing and sustainable materials innovation to discuss and answer possible concerns. It’ll take effort, but the positive change within the company will be worth it.
Embrace a Greener Future
Material innovations can propel the world to a greener future. From breathing new life into waste to designing products that are kinder to the environment, these strategies can guide you as you innovate sustainable products. Be creative, embrace new ideas and commit to continuous improvement.
Jack Shaw is the senior editor of the men’s lifestyle magazine Modded and has written extensively about electric vehicles, sustainable practices and maintaining a green lifestyle through your everyday actions. His writing can be found in Green Living Journal, Packaging Digest, EcoHotels and more. Connect with him via his LinkedIn.