Monday, August 4, 2025
As global manufacturing pushes for more sustainable practices, data collection, analysis, and management have become essential to achieving these goals. The industry faces several challenges when it comes to measuring environmental impact, particularly in terms of energy use and carbon emissions. However, these challenges also provide the opportunity for innovation and transformation in the way manufacturing companies approach sustainability. Seco, a leading provider of cutting solutions, is playing a key role in this transformation through a groundbreaking collaboration with the Advanced Manufacturing Research Centre (AMRC) in Samlesbury, UK.
At Seco, their purpose is simple yet powerful: “Together we make manufacturing fast, easy, and sustainable.” This goal is becoming increasingly important as manufacturers seek to reduce their environmental footprint. With sustainability becoming a critical focus for future legislation, Seco is taking steps to make data collection and analysis a central part of the manufacturing process.
Harnessing IoT for better insights
Seco’s partnership with AMRC aims to address the data management challenges in manufacturing by leveraging the power of the Internet of Things (IoT) and industrial communication protocols. Together, the two entities are working to create a comprehensive solution that will allow manufacturers to monitor and analyse every aspect of their machines and facilities for environmental impact. The collaboration focuses on collecting data from three key areas of the manufacturing process: the machining process itself, the machine environment, and the broader facility context.
This data is essential for assessing and improving energy efficiency, CO2 emissions, and overall environmental performance. By using IoT devices to gather data from each area, Seco is creating a “single source of truth” that will allow manufacturers to make informed decisions on how to reduce their environmental footprint.
1. Energy consumption and material usage
The first domain being monitored is the machine itself. Seco’s system tracks the energy consumption of individual machines in real-time, providing data on energy usage during specific sub-processes. This includes tracking energy consumed by cutting tools, cutting fluids, and other materials used in machining operations. With this data, manufacturers can convert energy consumption into tangible metrics such as real-time costs and CO2 emissions, adjusting their processes to optimise both energy use and environmental impact.
2. Monitoring the machine environment: Temperature and humidity
The second domain focuses on the immediate machine environment, which includes factors like temperature and humidity. These environmental conditions can significantly affect energy consumption as machines require specific conditions to operate efficiently. For example, fluctuations in temperature and humidity levels can increase the need for cooling, leading to higher energy costs. By tracking these environmental variables, Seco’s system allows manufacturers to understand the relationship between the machine’s surroundings and its energy consumption.
3. Facility-wide monitoring: identifying patterns and inefficiencies
The third domain is the facility as a whole. Seco’s system tracks the energy usage and patterns within the entire manufacturing plant, identifying areas where inefficiencies may exist. For instance, if the windows are left open or the HVAC system is not optimised, it may cause unnecessary increases in energy consumption. The data collected from facility-wide monitoring helps manufacturers identify high-level patterns that can lead to greater energy savings and cost reductions.
4. Understanding interactions between the machine, environment, and facility
Perhaps most importantly, Seco’s system looks at the relationships between these domains. For example, how does the humidity around a machine affect its cooling requirements? Are open windows or improper ventilation causing an increase in energy usage? These insights help stakeholders understand the interrelated factors that impact energy consumption and CO2 emissions, enabling them to make more informed decisions about how to optimize their operations for sustainability.
Optimisation driven by AI
Seco’s collaboration with AMRC is laying the groundwork for sustainable manufacturing in the future. Through constant data collection from equipment, surroundings, and facilities, Seco can spot hidden inefficiencies that could otherwise go overlooked. Manufacturers can instantly modify their operations with real-time access to this data, lowering emissions and energy consumption while increasing overall productivity. An automatic feedback system driven by AI is one of the major innovations Seco is aiming for. This system will continuously monitor and optimise manufacturing processes, ensuring that each adjustment moves the company closer to achieving its net-zero goals. Manufacturers will be able to strike a hitherto unattainable balance between cost, productivity, and environmental responsibility thanks to this degree of real-time optimization.
Life cycle assessment and green renewable manufacturing strategies
Seco’s data-driven approach doesn’t stop at monitoring energy usage and emissions. The system also incorporates life cycle assessments (LCA), which evaluate the environmental impact of each component used in the manufacturing process. By integrating LCA data with real-time machine data, Seco can provide precise environmental scores for each product and component. This helps manufacturers make more sustainable decisions when choosing materials and processes.
Furthermore, the collaboration with AMRC is opening the door to innovation in greener machining strategies. By gaining a deeper understanding of how different manufacturing processes impact the environment, Seco is leading the way toward more sustainable, cost-effective production methods.
Conclusion
Seco’s collaboration with AMRC represents a significant step forward in the manufacturing industry’s journey toward sustainability. By harnessing the power of IoT and real-time data, Seco is helping manufacturers reduce their carbon footprints, lower energy costs, and improve overall efficiency. The company’s commitment to sustainable manufacturing is not just about meeting regulations; it’s about making manufacturing faster, easier, and more environmentally responsible. As Seco continues to innovate, it is setting the stage for a future where sustainability is at the heart of every manufacturing decision.
Seco is demonstrating that data intelligence can propel meaningful, actionable sustainability by collaborating with the AMRC and its clients, paving the way for a more sustainable future for manufacturing globally.
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Tags: AMRC, carbon footprint, data-driven manufacturing, Energy efficiency, environmental impact, industrial IoT, Internet of Things, machining process, manufacturing innovation, Seco, sustainable manufacturing
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