Green manufacturing prioritises sustainability by minimising waste, reducing energy consumption, and limiting environmental impact, all while promoting the use of renewable and eco-friendly resources throughout the production process.
In food & drink manufacturing, sustainability initiatives such as heat recovery systems and smart automation are transforming operations. By integrating energy-efficient technologies into legacy production lines, manufacturers can reduce utility costs by up to 30%, meet ESG targets, and enhance operational resilience. This article will cover the principles and methods of green and sustainable manufacturing. We will also detail how Elmleigh’s and our parent company Leadec’s sustainable manufacturing practices can benefit multiple industries.
Key Green Manufacturing Practices in Food & Drink and Logistics
Process Optimisation
Process optimisation is a strategic approach to redesigning workflows for greater efficiency and productivity. At Elmleigh, our engineers take a data-driven view of your existing operations—identifying bottlenecks, removing inefficiencies, and streamlining production to deliver measurable improvements.
By refining workflows, our clients benefit from
- Reduced waste
- Improved product quality
- Lower operational costs
These gains translate into stronger financial performance and enhanced brand reputation.
Elmleigh works in close collaboration with system integrator partners to design and deliver fully integrated automated solutions. Whether it's food processing or parcel sortation, we ensure every component in your production line is best-in-class and tailored to your specific operational needs.
We provide end-to-end solutions to optimise your facility’s layout using advanced automated conveyor systems. By reconfiguring your existing setup, we help reduce errors, increase throughput, and elevate the overall quality of your distribution process.
Our team also specialises in the design, manufacture, and installation of brand-new conveyor systems—built to meet the demands of modern manufacturing environments.
Beyond installation, we implement intelligent automation tools to maintain peak performance and ensure long-term efficiency, especially during high-demand periods.
Energy Efficiency and Automation in the Manufacturing Industry
High-quality automation software makes a massive difference in our manufactured systems. Here are the critical sustainability functions we can implement into our automation software:
- Real-time monitoring of automated systems will keep accurate data on energy consumption and the efficiency of processes.
- Predictive maintenance can identify system issues before breakdowns, reducing waste and preventing key inefficiencies.
Benefits of Sustainable Automation in Manufacturing
When integrated correctly by Elmleigh’s in-house experts, automation can help your food & drink or logistics facility become more efficient and environmentally friendly. The following items are
- Operational cost savings – consuming less energy and reducing waste will reduce operational costs.
- Regulatory compliance – a productive automated system can help you adhere to the framework of environmental standards in the UK. These include the Food Industry Sustainability Strategy (FISS) and the sustainability strategies of the Food Standards Agency (FSA).
- Improved/sustained brand reputation – you can attract more environmentally conscious clients and customers.
- Innovation – adding new sustainable technology to your facility can give you an edge over your direct competition.
Elmleigh’s Sustainability Practices
Elmleigh champions industrial automation, highlighting the sustainability and efficiency it can bring to a business.
We offer a full turn-key solution for automated systems, which includes:
We have completed many automation integration projects, demonstrating our ability to install automated conveyor systems on time and to the highest standard. For example, we recently stripped a legacy system for a long-standing client and replaced it with a new automated system.
Sustainable Lighting
We worked with a snack food manufacturer in Coventry, replacing their ceiling lighting system. The new system is comprised of LED lights, with an operating functionality of over 60,000 hours. The system in question supports maintenance through its ease of installation and removal, and the lights are also recyclable. We completed the job over two years, and it cost £558,331.55 in total. This project was completed in collaboration with Brighter Business, with whom we work in close partnership on multiple LED lighting upgrades for clients. The project consisted of the following:
- We completed the work while the factory was in full operation, working around active production lines and ensuring they remained clean.
- Install food-grade lighting, which is glass-free and reduces the risk of contaminants within the food.
- Install LED lighting with low heat development and an average lifespan of roughly 60,000 hours. They use 75% less energy than an average bulb, resulting in significant energy savings and a substantial return on investment in under 3 years.
Car Chargers
We have installed many car chargers for our food and beverage clients to help them achieve their carbon reduction goals.
We have completed this at snack food manufacturers in:
- Coventry
- Leicester
- Nuneaton
The most common system we install is an array system. With each car added, the power is split evenly; each car then draws an equal amount of volts, ensuring fair distribution. Please read more about one of our recent car charger projects here.
Need a Sustainable Manufacturing Solution for Your Facility?
Don’t know how to start making your facility more sustainable and environmentally friendly? Get in touch with Elmleigh today to discuss our sustainable automation options.
Along with sustainably manufacturing automated systems, we specialise in design and installation. Our bespoke systems are a significant step towards lowering costs, minimising waste and increasing energy efficiency.
Contact us on 01455 847045 or complete our contact form, and one of our experienced and knowledgeable team members will be in touch with you to discuss your automation requirements.