ABB is advancing its Mission to Zero™ program at its Sasbach manufacturing site in Germany, demonstrating how on-site renewable energy, electrification and digital energy management can deliver meaningful emissions reductions while strengthening energy resilience.
The Sasbach site manufactures enclosures and energy distribution systems for local and regional markets, supporting ABB’s production footprint in Germany. As part of ABB’s global Mission to Zero™ program, the site is implementing a data-led decarbonization roadmap focused on energy efficiency, renewable electricity and smart energy management. Sasbach is one of 37 ABB sites worldwide currently participating in the program, which aims to significantly reduce operational emissions across ABB’s global footprint.
With manufacturing and production accounting for around one-fifth of global carbon emissions, improving energy efficiency and accelerating electrification are critical to achieving European climate targets. The Sasbach site shows how manufacturers can reduce emissions while maintaining reliable, competitive operations.
Taken together, the actions implemented at the Sasbach site deliver total CO₂ savings of approximately 3,786 tons. This includes around 2,700 tons of CO₂ savings from the purchase of certified renewable electricity from the grid, alongside annual emissions reductions of approximately 1,086 tons of CO₂ delivered through on-site measures. Of these yearly on-site savings, around 550 tons of CO₂ per year come from on-site solar generation, which has been expanded. The site now operates 3,410 photovoltaic modules, generating around 1,500 megawatt-hours of electricity annually. This is enough to supply approximately 400 homes for a year.
On-site generation will cover close to one-third of the site’s total electricity demand, reducing exposure to volatile energy prices and enhancing long-term energy security. A newly installed transformer station ensures stable and efficient integration of the renewable electricity into the site’s power infrastructure. The remaining reductions are achieved through electrified production upgrades, energy efficiency measures, and digital energy management. Together, these actions are strengthening energy resilience and supporting stable, reliable day-to-day operations.
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| ABB's Sasbach Plant. |
In parallel, ABB has continued to modernize production processes to reduce energy demand at source. A new powder-coating facility has expanded production capacity while significantly lowering energy requirements. Designed across two levels, the facility incorporates heat recovery and operates with substantially lower installed heating capacity than conventional systems, supporting both efficiency gains and production reliability.
Additional efficiency measures across the site include full LED lighting in production areas, building automation via the ABB i-bus® KNX, waste heat recovery from compressed air systems, and optimized process controls. Twenty-one onsite electric vehicle (EV) charging stations support low-emission mobility for employees and visitors.
Together, these initiatives have significantly improved energy productivity compared with 2019 levels, while helping stabilize operations and reduce operating costs. ABB's Building Automation System (BMS) and energy management solutions bring these measures together, providing real-time visibility into energy use and enabling continuous improvement and data-driven decision-making that supports efficiency, resilience, and operational stability.
Building on these achievements, ABB has defined a clear roadmap for the next phase of decarbonization at Sasbach. Battery storage systems are planned to store excess solar electricity and support production during peak demand and night shifts. Gas-based heating systems are being progressively replaced with electric heat-pump solutions, reducing reliance on fossil fuels over time. The site is also evaluating the potential for on-site wind generation to further strengthen energy self-sufficiency in the future.
The Sasbach site joins ABB’s growing global network of Mission to Zero™ locations spanning Europe, the Americas and Asia. Mission to Zero™ began as a local initiative at ABB’s Lüdenscheid factory in Germany and has since scaled globally. Together, Mission to Zero™ sites are already reducing more than 60,000 tons of CO2e emissions from our operations per year, demonstrating how electrification, digitalization and energy efficiency can deliver measurable progress toward low-carbon manufacturing.
Through continued investment in renewable electricity, electrified processes, and smart energy management, ABB’s Sasbach site is becoming a future-ready manufacturing location that combines environmental responsibility with strong operational performance, supporting a more resilient and efficient industrial base for the region.
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