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Im tschechischen Klášterec ist nach knapp eineinhalb Jahren Umrüstzeit die erste Null-Emissions-Fabrik des ZF-Konzerns entstanden. // In Klášterec in the Czech Republic, ZF Group opens first zero-emission plant after a renovation period of just under a year and a half.
At a Glance
Who: ZF, a technology company
What: Establishment of the first zero-emission manufacturing facility in Klášterec, Czech Republic
Where: Klášterec nad Ohří, Czech Republic
Why: To support ZF’s ambition for climate neutrality by 2040 and reduce greenhouse gas emissions
When: Renovation completed in less than 18 months; target for full green energy usage by 2025
The Challenge
One of the primary challenges facing ZF is converting its existing global plants to operate with climate-neutral energy. ZF has set a target to achieve climate neutrality across all value chains by 2040, necessitating substantial changes to its operations. This requires equipping plants with the ability to generate electricity and significantly reducing emissions from manufacturing sites.
The Solution
In Klášterec, the challenge was overcome by installing 3,400 solar modules on the campus, covering approximately 20% of the plant’s annual electricity needs. Any additional electricity is sourced from renewable providers, predominantly wind and hydroelectric power.
How the Project Works
The renovation of the Klášterec site involved installing 3,400 solar modules on the campus, meeting nearly 20% of the plant’s yearly electricity needs. Any external electricity is sourced from renewables, mainly wind and hydroelectric power. ZF aims to fully switch to green electricity by 2025, five years ahead of schedule, through a combination of in-house generation and contracts with renewable energy providers.
Additionally, the Czech e-mobility plant replaced its fossil fuel-dependent gas heating system with heat pumps, halving the plant’s annual heating costs. During colder months, the plant utilises naturally cold external air for cooling. Various measures for improved insulation and heat recovery complement this local climate concept.
Operating in Klášterec since 1992, the remodelled plant now employs nearly 700 workers, producing power electronic components for electric motors used in ZF plants in Germany and Serbia, serving international car manufacturers.
The Results
The initiative has yielded significant results, including a 50% reduction in the plant’s annual heating costs following the replacement of the gas heating system with heat pumps. Furthermore, the installation of 3,400 solar modules has met approximately 20% of the plant’s yearly electricity requirements, marking progress towards its goal of achieving climate neutrality.
Business Benefits
The renovation of the plant into a zero-emission facility not only reinforces ZF’s commitment to attaining climate neutrality across its entire value chains by 2040 but also positions it as a model for sustainable practices within the company.
By serving as a blueprint for all ZF plants globally, the facility facilitates the gradual transition to sustainably sourced energy, enhances process efficiency, promotes product electrification and encourages the use of recycled materials. These strategic initiatives also enhance ZF’s competitiveness, bolstering its reputation as a leader in sustainable technology solutions.
Investment/Savings
Despite initial capital investment in renewable energy infrastructure and efficiency upgrades, the project generates substantial long-term savings through reduced energy expenditure and enhanced operational efficiencies, ensuring a favourable return on investment.
Industry Context
With global production sectors accounting for one-fifth of carbon emissions and consuming 54% of the world’s energy sources, there’s a pressing demand for manufacturing companies to tackle the decarbonisation challenge. ZF’s Klášterec initiative mirrors wider industry movements towards sustainability, confronting the environmental impact of manufacturing and supporting industry-wide objectives for transitioning to a circular economy.
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