Energy Efficiency Analysis in Industry 4.0 set up leveraging Industry 5.0 methods for Sustainable Manufacturing: Case Study

Abstract

This study explores the integration of Industry 5.0 principles into existing Industry 4.0 configurations to address excessive heat dissipation, energy efficiency and promote carbon neutral manufacturing. Industry 5.0 represents a paradigm shift, emphasizing human-centered approaches, energy efficiency and environmental sustainability alongside traditional productivity goals. The case study analyzes energy consumption in an Industry 4.0 setup, quantifies heat waste and applies innovative solutions to optimize energy use. Considering digital manufacturing through the Industrial Internet of Things (IIoT), big data analytics, smart automation technologies in cyber-physical production systems and sustainable practices, the study aims to mitigate and minimize energy waste and carbon emissions. Through quantitative analysis, it identified energy inputs, mapped energy transformations, and assessed energy waste hotspots. Despite all the benefits of Industry 4.0, it showed that responsible practices and new initiatives are required to reuse and capitalize on that wasted energy or heat, underscoring the importance of integrating Industry 5.0 principles for sustainable manufacturing.