Efficiency is a bottom-line issue that can determine whether a manufacturer thrives or falls behind, writes Adrian Wright of Daltons Wadkin, and new hardware advances could slash material waste and energy bills
In an era where manufacturing efficiency is more crucial than ever, businesses across the industry are looking for ways to reduce costs, minimise waste and enhance productivity.
Automation and Industry 4.0 have become buzzwords as well as dominant trends, with manufacturers increasingly integrating robotics, data-driven decision-making and smarter machinery into their processes.
It was previously predicted that by 2025, some 50% of manufacturers globally would adopt IoT technologies as part of their Industry 4.0 strategies. Adoption is driven by the potential for productivity increases of 20% to 35% and reductions in downtime of up to 50%.
However, one aspect that often gets overlooked in these discussions is energy efficiency — an area where modern CNC routers and fibre lasers are redefining what’s possible.
While many businesses recognise the importance of optimising efficiency, few fully quantify the financial and environmental cost of material waste
Hidden costs
Waste reduction is an ongoing challenge in manufacturing. While many businesses recognise the importance of optimising efficiency, few fully quantify the financial and environmental cost of material waste.
Take, for example, a manufacturer that we at Daltons Wadkin recently spoke to about improving accuracy and driving efficiency gains. The company was discarding 20% of parts for every 1,000 parts produced, meaning that 200 parts per batch were going straight to waste. At another company, only three out of 16 precision blades met its required tolerances, resulting in a staggering 75% to 80% scrap rate.
These inefficiencies aren’t just costly in terms of raw materials. They also have a direct impact on operational costs, including machine running times, energy consumption and additional labour. Data shows that companies can spend between 4% and 10% of their annual turnover on waste if they lack proper waste management strategies.
Industry reports suggest that manufacturing waste accounts for billions in losses annually. According to some reports, the manufacturing industry generates around 17% of global waste, further exacerbating supply chain constraints and environmental impact.
Finding alternatives
Traditional manufacturing processes often rely on outdated machinery with high energy consumption and inconsistent performance. In contrast, modern CNC routers have been engineered to optimise material usage, improve accuracy and significantly lower power consumption.
One of the primary advantages of CNC routers in multi-material manufacturing is their precision. By reducing deviation in cuts and machining, modern CNC routers minimise scrap, leading to both cost savings and sustainability benefits.
Furthermore, CNC routers integrate seamlessly with smart factory systems, offering real-time data insights on energy use, maintenance needs and material efficiency. Beyond material savings, modern CNC routers also offer substantial energy efficiency benefits.
The shift towards leaner, greener machines is evident in the latest developments across the industry.
During a recent trip to visit Italian press brake supplier Schaivi, I saw first-hand the importance of energy efficiency. The point driven home to press brake users is how fully electric small- and medium sized machines are more efficient than full hydraulic machines and are offered in higher tonnage by comparison.
Smart automation is now also allowing press brakes to achieve job changeovers with zero operational setup time – a remarkable leap in efficiency.
For manufacturers, the financial case for energy-efficient machinery is clear. The cost of running high-energy, inefficient equipment quickly adds up, especially when factoring in rising electricity prices and sustainability targets.
As manufacturers face growing pressure to cut costs while improving sustainability, those who invest in smarter solutions today are more likely to secure a long-term competitive edge.
Automation technologies have been shown to be capable of reducing energy consumption by up to 20% in manufacturing processes, yet despite such easy wins, many manufacturers still operate in a reactive mode, dealing with inefficiencies only when they become too costly to ignore. However, the businesses that will thrive in the future are those that proactively seek smarter solutions now.
The energy efficiency revolution in manufacturing is here, but only those who take action will reap its benefits.
As automation, robotics and data utilisation continue to define the industry, businesses must look beyond simply acquiring new machinery and instead invest in solutions that drive real, measurable efficiency and productivity gains. The future of sustainable, cost effective manufacturing is within every manufacturer’s reach. For those looking to stay ahead of the curve, now is the time to rethink their approach to efficiency.
About the author:
Adrian Wright is a fibre laser and sheet metal specialist at Daltons Wadkin, a Nottingham, UK leader in implementing precision-driven CNC and laser solutions with the aim of helping manufacturers to cut down on waste and improve efficiency.
This article first appeared in DEVELOP3D Magazine
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