RESEARCH NEWS
Supporting sustainability in manufacturing
University of Sheffield AMRC engineers in the UK have found a way of using weather forecasts to reduce the environmental impact of manufacturing processes— without hindering productivity.
In the UK, energy production is split between renewable sources, such as wind and solar, and fossil fuels such as coal and gas. However, the power output of renewable energy sources fluctuates based upon weather conditions, directly affecting the carbon intensity of the electricity grid; less favourable weather means greater reliance on fossil fuels which increases carbon emissions.
This variability makes it crucial to understand when the grid is running on more renewables making it‘ more sustainable’, versus when it’ s‘ less sustainable’ due to greater reliance on fossil fuels, to make informed energy choices.
The University of Sheffield Advanced Manufacturing Research Centre( AMRC) has therefore developed a system to strategically schedule energy-intensive manufacturing tasks for periods when the grid’ s carbon footprint is lowest— directly addressing the challenge of reducing the carbon dioxide equivalent( CO₂E) of manufacturing processes.
Tace Morgan, sustainability theme lead at
AMRC North West’ s real-world manufacturing data helped to validate the project’ s approach to sustainable scheduling.
the University of Sheffield AMRC, said:“ A key challenge in improving manufacturing sustainability is reducing its carbon footprint. While using renewable energy offers a lower carbon intensity, its availability varies, making it an inconsistent source.
“ Our research directly addresses this by leveraging the predictable link between carbon intensity and weather patterns. This allows us to intelligently schedule energy-intensive tasks for greener times, significantly lowering environmental impact without hindering productivity,” continued Morgan.
The AMRC has also developed a web interface tool that showcases how manufacturers can utilise the technology to inform their scheduling decisions, outlining the trade-offs between production timelines and environmental impact.
Further research is needed to seamlessly integrate such a system into complex, real-world manufacturing environments and incorporate data from entire production facilities, where multiple factors influence schedules.
This groundbreaking work builds upon the AMRC’ s previous research under Project Butterfly, which established the link between weather patterns and predictable energy carbon intensity. Funded by the national High- Value Manufacturing Catapult network, the current research further refines this concept, directly supporting the UK’ s journey towards its net zero goals.
As part of the project, the AMRC developed a machine learning model capable of forecasting energy carbon intensity over 48 hours. The model analyses publicly available weather forecast data alongside energy production trends to identify optimal times for running machinery with the lowest associated CO₂E emissions. n
www
. amrc. co. uk
Prize-winning research projects in focus
At EMO Hannover 2025 in Germany, the VDW Research Institute has awarded prizes to two research projects as“ Projects of the Year”. The awards were presented to the winners on 25 September 2025 by Dr. Stephan Kohlsmann, Chairman of the Executive Board of VDW-Forschungsinstitut e. V., and its CEO, Dr. Alexander Broos.
Project of the Year 2024
Martin Wagner, Nico Wagner and Dr. Robert Tehel from the Fraunhofer Institute for Machine Tools and Forming Technology( IWU) in Chemnitz were awarded the prize for a project entitled“ Minimizing set-up times on forging hammers using a sensitive die clamping system( sGs)”. The aim was to make tool changes on forging hammers more efficient, safer and more reproducible.
The researchers developed a measurement system enabling the clamping situation to be recorded qualitatively and quantitatively in the process. FEM simulations based on this data provided new insights into clamping conditions. This led to the development of a new type of clamping system that is able to withstand the extreme dynamic and thermal loads in the forging process.
The solution offers significant advantages: shorter set-up times due to fewer readjustments, increased process reliability thanks to reproducible pre-tensioning and increased work safety, as uncontrolled hammer blows when driving in wedges are avoided. The concept also unlocks new potential for automation and cost reduction.
Project of the Year 2023
The winner of the second project award was Simon Thom, who worked on a project entitled“ Dimensioning of protective devices for stationary grinding machines” at the Institute of Machine Tools and Factory Management( IWF) at the Technical University of Berlin. The project focused on how protective enclosures can be designed so that they can reliably protect operating personnel and machines without being unnecessarily large.
The researchers combined translational impact tests with finite element simulations. This resulted in a regression model that describes the relationship between grinding
Image: Rainer Jensen / VDW.
Award ceremony for the VDWFI“ Project of the Year” at EMO Hannover 2025. L-R: Dr. Alexander Broos; Dr. Robert Tehel; Nico Wagner; Martin Wagner; Simon Thom and Dr. Stephan Kohlsmann.
wheel parameters and the required wall thickness. It therefore became possible to develop resource-saving specifications for the construction of protective devices. The results have already been incorporated into the international standard, ISO 16089.
The award-winning projects were funded by the German Federal Ministry for Economic Affairs and Energy as part of the“ Industrial Collective Research” funding programme. n
https:// emo-hannover. com
16 | ismr. net | ISMR November 2025