ABB’s commitment to reducing plastic waste

At ABB, we recognize that true sustainability starts from within. In 2024, 11 of our sites reported environmental improvement projects focused specifically on plastics—ranging from eliminating single-use plastics to reducing plastic in packaging materials.

For example, at our Smart Buildings Factory in Porvoo, Finland, we’ve managed to cut mixed plastic waste by 50 percent and improved its recycling rate by almost 20 percent in 2023. This is achieved by adopting innovative injecting molding processes which set aside plastic waste from production lines to convert into oil (through chemical recycling) for use by the broader plastics industry.

In the same factory we’ve also shifted to recycled plastic for manufacturing junction boxes, reducing their carbon footprint by 40 percent. This innovation also conserves 90 liters of water per unit while maintaining high performance even in extreme temperatures. Our SAGA™ range of switches and sockets, made from bio-circular materials, is projected to save 400 tons of CO₂e annually by 2030 - equivalent to heating 42,438 electric saunas.

In India, at our Nelamangala site in Bangalore which has successfully transitioned to 100% renewable electricity, teams are also busy working on optimizing packaging with less material and experimenting with bio-degradable and recycled plastics.

In the UK our Hams Hall facility in Coleshill, has embarked on a transformative journey, integrating innovative practices that not only enhance efficiency but also minimize environmental impact. The facility’s commitment to sustainability is evident in every aspect of its operations; all waste is processed sustainably, meaning zero waste is sent to landfill. Surplus packaging materials are recycled while plastic, banding and cardboard are converted into renewable energy and sold back to the grid. 

But our efforts don’t stop at our own operations. Through our products and partnerships, we help customers reduce waste across the entire product lifecycle - from design and sourcing to packaging, logistics, and end-of-life solutions.

Innovation in action: sustainable packaging and beyond

We’re proud to support customer initiatives like the collaboration between ABB and IPD in Australia, which has introduced more sustainable packaging to reduce landfill waste. By improving their packaging strategies and removing the plastic air pouches for void fill, our channel partners were able to adopt sustainable packaging practices that significantly reduce, reuse, and recycle materials. 

In another example, our collaboration with FirstPak in China is helping scale production of sugarcane-based packaging - a renewable and compostable alternative to petroleum-based plastics. Our partnership is helping to replace single-use plastics in the world’s largest takeout operations. By deploying 200 robots, FirstPak has doubled production line efficiency and cut energy costs by up to 30 percent, all while producing degradable, eco-friendly packaging.

And through our collaboration with Parason in India, we are helping ramp up production of compostable tableware used in restaurants, transport, and catering industries. This helps contribute to India’s ambition of reducing 3.5 million tons of plastic waste per year.

Beyond packaging, we are looking into the marine ecosystem. Every year, around 1 million tons of abandoned or lost fishing gear - equal to 50,000 double-decker buses - pollutes our oceans, threatening marine life and fueling the global plastic crisis. We’re helping to change that. Our new PMA® EcoGuard™ PA6 cable protection system is made with 50 percent recycled polyamide, primarily sourced from discarded fishing nets, turning ocean waste into a sustainable, high-performance solution for protecting electrical cables and wires.

By choosing recycled materials, we’re not only reducing plastic pollution but also lowering our environmental impact. Compared to conventional systems, EcoGuard™ PA6 cuts upstream Scope 3 greenhouse gas emissions by 30 percent and reduces freshwater use by 50 percent.

The role of motors and drives in achieving more sustainable plastics production 

Motors and drives also play a key role in making plastic production more sustainable by improving efficiency and reducing waste. While mechanical recycling is still common, innovations like bioplastics, chemical recycling, and scrap-reduction machinery are helping improve recycling rates and material quality. These technologies require precise control over temperature, torque, and energy use.

That’s where variable speed drives (VSDs), motors, and programmable logic controllers (PLCs) come in. For example, Sarem Makina in Turkey uses ABB drives and motors to optimize performance in plastic pipe extrusion - ensuring high product quality and energy efficiency. Smart motion control is helping bring plastic production closer to circularity.

Looking ahead

We are shaping a more structured approach to plastic reduction that spans the entire lifecycle of our products - from eco-design and circular sourcing to optimized packaging and responsible disposal. Because sustainability isn’t just about what we remove - it’s about what we redesign.

Footnotes

1. OECD Data explorer

2. UNEP report From Pollution to Solution: A global assessment of marine litter and plastic pollution

3. The fundamental links between climate change and marine plastic pollution, Science of The Total Environment

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