ABB drives towards net zero at Bulgarian manufacturing plant

Image credit: ABB Electrification

ABB’s Electrification factory in Rakovski, Bulgaria, is taking significant steps towards achieving net zero operations, reducing CO2e emissions by 1,250 tonnes.

This progress stems from energy optimization measures, including fully metered and controlled energy use, a building management system, heat pump installations, LED lighting upgrades, and the addition of electric vehicle (EV) charging points, the company said in a media release.

The factory has cut its energy consumption by 22 per cent while boosting production revenue, leading to a 43 per cent improvement in energy intensity compared to a 2019 baseline.

The 39,000-square-meter plant, comprising two production buildings, manufactures low and medium-voltage products for data centres, industrial and manufacturing plants, critical infrastructure, and buildings.

Since 2021, the Rakovski site team has been aligning with ABB’s Sustainability Agenda.

Their first major initiative was upgrading all conventional lighting to energy-saving LED fixtures and integrating the ABB i-bus KNX system for intelligent lighting control.

A key milestone in the facility’s Mission to Zero journey was the installation of ABB Ability Energy and Asset Manager solutions.

This innovation enhances energy efficiency optimization and predictive maintenance by providing real-time data, thereby improving decision-making by allocating energy resource costs to various groups—production, lighting, heating, ventilation, air-conditioning (HVAC), and administration.

These efforts have contributed to the plant achieving ISO 50001 certification.

To further reduce HVAC energy consumption and up to 80 per cent of CO2e emissions from gas usage, the factory installed heat pumps last year.

It also implemented centralized control and monitoring for heating and cooling, along with a fluid distribution system.

These systems are managed by ABB’s building management system, ABB Cylon, which was installed in both buildings at the beginning of 2024.

This end-to-end solution tracks and forecasts energy consumption, paving the way for future renewable energy use and ensuring a stable energy supply.

“Our end-to-end solutions contribute to the effective tracking and forecasting of energy consumption,” said Mike Mustapha, President of ABB Electrification’s Smart Buildings Division.”

He continued, “The achievement in our Bulgarian operations not only showcases how we reduce carbon emissions in our own built environment, but it underscores our ability to help customers and partners achieve their own sustainability goals.”

In line with ABB’s 2030 fleet electrification commitment, the Rakovski branch has begun converting its vehicle fleet to electric vehicles.

It has installed 17 AC and DC EV charging stations, supporting EV charging for both the local community and passing traffic.

These milestones mark a significant step in ABB Bulgaria’s net zero journey, earning them the designation of an ABB Mission to Zero site.

The ABB Mission to Zero program supports the company’s commitment to reducing Scope 1 and Scope 2 greenhouse gas emissions by 100 per cent by 2050.