Spanning 142,000 square feet, the facility now part of ABB’s Mission to Zero program, sources close to 80% of its electricity from an on-site solar installation. But the shift is less about a single energy project and more about a broader operational strategy—one that integrates energy management into day-to-day decision-making rather than treating it as a separate initiative.
Older industrial assets are often viewed as barriers to efficiency gains, particularly when retrofits risk disrupting production. At the Florence site, the approach avoided full system replacement in favor of targeted improvements rolled out over time.
Digital monitoring and automated controls enabled operators to track energy use in real time, identify inefficiencies, and respond with precision. This level of visibility allowed investments to be directed where they would have the most impact, without interrupting ongoing operations.
The result is a model that challenges the assumption that modernization requires starting from scratch. Combining electrification, on-site generation, and data analytics created a layered system that improves performance while extending the useful life of existing infrastructure.
One of the more notable outcomes is the site’s ability to increase production without a corresponding rise in energy consumption. Energy productivity improved by 74%, while revenue grew by 140% alongside an expanded product portfolio.
Generating a large share of electricity on-site has helped reduce exposure to grid volatility and rising energy costs. At the same time, digital optimization tools continue to fine-tune consumption patterns, supporting both efficiency and resilience.
Additional efforts—including waste-to-energy processes and expanded recycling programs—have moved the facility closer to zero waste to landfill. These initiatives broaden the scope of sustainability beyond energy, linking resource efficiency with financial outcomes.
While the Florence project highlights what is achievable, its replicability will vary. Access to solar resources, capital investment, and digital infrastructure differs widely across facilities. The effectiveness of incremental upgrades also depends on the quality of operational data and the ability to act on it.
Even so, the broader takeaway is gaining traction across the industrial sector: sustainability investments are increasingly judged on their operational value. Efficiency gains, risk reduction, and long-term cost control are becoming central to the business case.
For organizations managing aging assets, the implication is clear. Progress does not require waiting for large-scale transformation. In many cases, a series of targeted, data-driven improvements can deliver measurable results while keeping production on track.
