Industrial automation is reshaping India’s manufacturing landscape by enabling greener, more sustainable factories.

India’s journey toward becoming a global manufacturing hub is accompanied by an urgent need to address sustainability challenges. With industrial sectors accounting for a substantial portion of energy consumption and emissions, the country’s push for ‘AatmaNirbhar Bharat’ must align with sustainable practices. Industrial automation, with its potential to optimise operations, reduce waste, and improve energy efficiency, is playing a pivotal role in enabling greener factories across India.

The Need for Sustainable Manufacturing in India

India's manufacturing sector, contributing nearly 17% to the GDP, is a cornerstone of the country's economic growth. However, the rapid industrialisation has led to significant environmental concerns, including high carbon emissions, energy wastage, and resource depletion. Initiatives such as the National Action Plan on Climate Change (NAPCC) and commitments under the Paris Agreement highlight India’s resolve to balance industrial growth with sustainability.

As businesses face increasing scrutiny from consumers, investors, and regulators, adopting greener manufacturing practices is no longer optional. Automation technologies offer Indian manufacturers the tools to meet sustainability goals while maintaining competitiveness in a global market.

How automation drives sustainability in indian manufacturing

1. Resource Optimisation Through Automation

In India, industries such as automotive, textiles, and FMCG rely heavily on raw materials and energy. Automation technologies like IoT, AI, and robotics are transforming how these resources are used. A few well-known names have already started implementing these new technologies to bring in the desired results like:

Tata Steel: Tata Steel has implemented IoT-enabled sensors in its Jamshedpur plant to monitor and optimise raw material consumption. By leveraging predictive analytics, the company has reduced wastage and enhanced efficiency in its steelmaking processes.

Maruti Suzuki: India’s leading car manufacturer uses advanced robotics in its assembly lines. These robots ensure precision in welding, painting, and assembly processes, reducing material waste while enhancing product quality.

2. Energy efficiency through smart systems

Energy efficiency is and has always been a key focus for Indian manufacturers, especially with rising energy costs and government policies promoting renewable energy adoption. Automation technologies enable industries to monitor and manage energy use effectively.

Hindustan Unilever (HUL): HUL’s factories in India, including the one in Dapada (which has been recognised as a Sustainability Lighthouse by World Economic Forum), utilise automation to optimise energy consumption. IoT-based systems track energy usage in real time, helping reduce carbon emissions and operating costs.

Amul Dairy: At its Gandhinagar plant, Amul uses automated systems to control refrigeration and processing, minimising energy wastage and ensuring sustainable dairy production.

3. Waste reduction through automation

India’s zero-waste movement in manufacturing has gained momentum, driven by government initiatives like the Swachh Bharat Abhiyan and Extended Producer Responsibility (EPR). Automation supports waste reduction by enabling precision and recycling. The same has been implemented by many corporates making them greener than others

JSW Steel: JSW’s Vijayanagar plant, one of the largest steel plants in the world, uses automated systems to recycle industrial byproducts. For instance, slag from steelmaking is converted into cement, contributing to circular manufacturing.

Asian Paints: The company employs robotics in its paint mixing and filling operations, minimising waste and ensuring consistent quality.

4. Water conservation using smart technologies

Water scarcity is a pressing issue in India, and industries are among the largest consumers of this vital resource. Water eventually has become a key resource for many industries without which they can’t function further. Automation has emerged as a silver lining which helps them conserve water by monitoring usage and minimising wastage.

ITC Paperboards and Specialty Papers Division: ITC’s plant in Bhadrachalamwhich was adjudged by CSE (The Centre for Science & Environment) as India’s most environment friendly paper mill, has implemented automated water recycling systems, achieving one of the lowest water consumption levels per tonne of paper produced globally.

PepsiCo India: The company’s manufacturing units employ IoT sensors to track and optimise water usage, aligning with its global sustainability goals.

Enhancing worker safety and productivity

Sustainability in manufacturing extends beyond environmental considerations to include social and economic dimensions. Industrial Automation contributes to sustainable manufacturing by improving worker safety and productivity.

1. Safer Work Environments: Automated systems handle hazardous tasks, reducing the risk of workplace accidents. This is particularly beneficial in industries like chemicals and heavy machinery, where human exposure to dangerous conditions can be minimised.

2. Skill Development: Automation supports workforce upskilling, enabling employees to focus on high-value tasks. This enhances job satisfaction and productivity, creating a more sustainable labor model.

Challenges to automation adoption in India

While automation presents immense opportunities for sustainable manufacturing, challenges persist. These are attributed to 3 major which are:

1. Taken as cost and not investment: Small and medium enterprises (SMEs), which form the backbone of India’s manufacturing sector, often show reluctance in investing in these technologies, as they see the new technology as a cost and not as an investment in assets which will help them grow further and become sustainable in a far much better pace.

2. Skill gap: Not many are equipped with knowhow and technical knowledge of operating these new technologies. There is a need for widespread workforce skilling and re-skilling to operate and maintain automated systems.

3. Infrastructure deficits: Reliable power supply and digital infrastructure are prerequisites for effective automation, which remain inconsistent in many parts of India, making it one of the biggest hurdles for a widespread adaptation.

Opportunities for growth

Despite these challenges, India is well-positioned to embrace automation-driven sustainability. Government initiatives such as the Make in India campaign, the Production Linked Incentive (PLI) scheme, and the National Electric Mobility Mission Plan (NEMMP) provide a conducive environment for adopting automation technologies.

Collaborations between industry leaders, academia, and startups are also fostering innovation in automation. Indian companies must capitalise on these opportunities to drive sustainable growth.

A roadmap for Indian manufacturers

To maximise the benefits of automation for sustainable manufacturing, Indian companies should:

1. Set Clear Sustainability Goals: Define measurable targets aligned with global best practices and local regulations.

2. Adopt Scalable Solutions: Start with pilot projects and gradually scale automation technologies.

3. Foster Collaboration: Partner with technology providers, government bodies, and research institutions to access cutting-edge solutions.

4. Invest in Skill Development: Upskill the workforce to bridge the talent gap in operating automated systems.

Conclusion

Industrial automation is reshaping India’s manufacturing landscape by enabling greener, more sustainable factories. From optimising resource use to reducing waste and energy consumption, automation technologies align economic growth with environmental stewardship.

As India aspires to become a global manufacturing leader, the integration of automation in sustainability strategies is crucial. Success stories from leading companies demonstrate the transformative potential of these technologies. By embracing automation, Indian manufacturers can reduce their environmental impact, improve operational efficiency, and ensure long-term competitiveness in the global market.

Sustainable manufacturing is not just an aspiration—it is a necessity for India’s future. Automation provides the tools to achieve this vision, creating a greener and more prosperous industrial ecosystem.

For additional insights, please contact: Ashwini Singh, AGM – Sales & Marketing, Rexel. Cell: +91-7888025310. Email: ashwini.singh@rexel.co.in 

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