Role of modern technologies & automation in green engineering

  • Articles
  • Jan 16,24
The convergence of modern technologies and digital twins is more than just a technological achievement; it represents a paradigm change toward engineering that is wiser, greener, and more responsible for future generations says Avi Dahiya.
Role of modern technologies & automation in green engineering

In a world where 73 per cent of millennials prioritise environmentally conscious businesses, going green is more than a trend—it's an essential shift. Embracing LOHAS (Lifestyles of Health and Sustainability) principles aligns strategically with the values of eco-conscious consumers. Likewise, green engineering involves designing and implementing processes/products that minimise pollution, promote sustainability, and protect human health, all while maintaining economic viability. It's not just a benefit to your business; it contributes to a positive global shift by integrating technological advancements with eco-friendly practices.

Imagine this – “by embracing technologies that benefit both your business and the Earth, you not only appeal to a growing consumer base but also contribute to a positive global shift.”

The current manufacturing landscape
The manufacturing industry is changing dramatically, driven by the dual goals of becoming a global hub and embracing sustainability. Innovation is happening quicker than ever before since the advent of game-changing technologies like digitalisation, robotics, AI, and 3D printing. These technological wonders are more than just terms of the moment; they are the driving force behind resolving centuries-old environmental issues.

As we step into an era where climate change, resource depletion, and pollution are urgent problems, ‘SUSTAINABILITY’ is the talk of the town. And guess who's leading the charge? ENGINEERING! With its arsenal of cutting-edge technologies, engineering is reshaping industries and guiding us toward a greener, more sustainable world.

Challenges in the manufacturing sector
The manufacturing sector, particularly in heavy industries such as power, chemicals, oil and gas, and mining, faces unprecedented challenges amid technological shifts and the imperative to address climate change. The need to reshape traditional business models was evident long before the pandemic, and in the post-pandemic era, this imperative has only intensified. Recently, there has been an announcement of a carbon emission tax on manufacturing, initially affecting industrial materials the most. While this tariff poses challenges, especially for countries majorly producing steel or iron, it also presents an opportunity to curtail emissions, thereby positively impacting the environment. The geopolitical implications of such taxes are particularly felt in developing countries.

Engineers now led the charge, managing time, cost, and reporting with vast amounts of engineering data to drive the energy transition and meet digital transformation needs effectively. Recognising these challenges, it is crucial to understand how emerging technologies can propel us toward a future of 'Green Engineering.' This journey holds the promise of a world where progress and environmental responsibility coexist, meeting the expectations of a generation deeply concerned about the planet. Staying informed about the pertinent trends, technologies, and opportunities is imperative to leverage modern engineering as a force for positive change.



Government vision and global manufacturing hub
The government envisions India as a global manufacturing hub, a powerhouse driving innovation and sustainability. To achieve this ambitious goal, a multi-faceted approach is imperative. This involves creating an ecosystem that fosters innovation, incentivises sustainable practices, and supports the integration of cutting-edge technologies into manufacturing processes. Investment in research and development, collaboration between industries and academia, and the formulation of policies that encourage sustainable practices will be key elements in transforming this vision into reality.

The government's role extends beyond policy formulation; it involves active participation in global initiatives for sustainable development. Collaborating with international partners, sharing best practices, and aligning with global sustainability standards will position India as a responsible global player in the manufacturing landscape.

Sustainable development goals and modern technologies
To achieve sustainable development goals, a comprehensive understanding of modern technologies is crucial. Each technology plays a unique role in reshaping the manufacturing landscape towards sustainability:

  • 3D Printing: Also known as additive manufacturing, 3D printing significantly reduces material wastage. Material wastage in 3D printing is minimal due to its additive manufacturing process. It enables decentralised manufacturing, offering the flexibility to produce small quantities and promoting green design. This technology revolutionises traditional manufacturing methods, aligning them with sustainability goals.
  • One of the early adopters of this technology is the aerospace and aviation industry. 3D printing in the aviation industry ensures prototyping and end-use applications and helps in the manufacturing of stronger and lighter parts. With 3D printing, components can be tailored for a specific aircraft or a type of aircraft.
  • Digitalisation: The integration of digital technologies into manufacturing processes enhances efficiency, reduces waste, and allows for real-time monitoring. Energy monitoring systems, like smart meters, drive the digitalisation of manufacturing for enhanced sustainability. They enable real-time tracking, optimising energy use, reducing costs, and ensuring equipment longevity. Automated alerts prevent issues, support environmental goals, aid compliance, and facilitate resource-efficient operations. In essence, these systems are pivotal in creating a sustainable and responsible manufacturing ecosystem.
  • Robotics: While traditional factories grapple with human limitations, such as fixed working hours, the integration of robotics promises 24/7 operations without fatigue. This shift enhances production quality, ensuring precision, reducing distractions, and minimising errors and defects, resulting in top-notch products. The use of robotics leads to a sustainable process as it results in a lesser number of rejections, contributing to overall operational efficiency and the production of high-quality goods.
  • Precision manufacturing through robotics minimises material wastage, improves accuracy, and enhances overall efficiency. The use of robots in manufacturing processes reduces environmental impact by streamlining operations and ensuring optimal resource utilisation.

  • Artificial Intelligence (AI): AI contributes to energy conservation by building and optimising machines that consume less energy. Through simulations and data analytics, AI identifies patterns for energy optimisation, leading to more sustainable manufacturing practices. Simulations and models guided by AI not only enhance energy conservation but also lead to a reduction in material usage, aligning with environmentally conscious manufacturing practices.
  • To foster productive collaboration between humans and robots, AI technologies are pivotal. Going beyond traditional dashboards, AI streamlines processes, minimises downtimes, forecasts demand accurately, optimises the workforce, and enhances supply chain intelligence. Analysing extensive data streams, transforms them into valuable insights, facilitating early fault detection and informed decision-making. In doing so, AI creates a manufacturing environment where human-robot synergy thrives, laying the foundation for the factories of the future.
  • Blockchain: While not explicitly mentioned, blockchain technology can play a crucial role in ensuring the transparency and traceability of the supply chain. Blockchain enables reverse traceability, facilitates the integration of carbon credits, and proves valuable for macro-scale tracking. This, in turn, contributes to sustainable and ethical manufacturing practices, aligning with global standards.
  • Implementing digital twins
    As we look into the intricacies of each technology, it becomes evident that their collective integration is pivotal for achieving sustainable development goals. These technologies are not isolated solutions but interconnected components of a holistic approach towards green engineering.

    Employing digital twins involves real-time updates using cloud systems and IoT, ensuring accuracy in heavy industries. Digital twins are virtual replicas of physical entities, like a power plant or refinery, used to streamline planning and execution. This technology tackles challenges of data silos, saving engineers' time, and enhancing decision-making. Amid technology trends and climate change, industries are adopting digital twins to drive energy transition, meet digital transformation needs, and overcome complexities in time, cost management, and reporting. Digital twins are indispensable for maintaining current information, making informed decisions, and refining change management strategies.

    Benefits of digital twins for engineers:-

  • Real-time decision-making: Empowering engineers with real-time information, companies adopting digital twin technology have significantly reduced decision time for optimal designs to less than a minute. This streamlined process is particularly beneficial in handover scenarios that involve cross-referencing information from multiple stakeholders.
  • Enhanced collaboration: Early-stage digital prototypes, a creation of digital twins, fosters collaboration among stakeholders, including customers. This collaborative environment allows engineering teams to validate complex asset designs in the Front-End Engineering Design (FEED) phase, ensuring all stakeholders work in a single platform with updated designs.
  • Improved planning efficiency: Industrial organisations employing digital twins achieve a 10-30 per cent increase in planning efficiency and a 15 per cent reduction in staff hours. Cloud solutions and visualisation tools play a pivotal role in enabling seamless project completion within budget and on time, thereby reducing extra work hours and uncertainty.
  • Contribution to sustainability goals: Digital twins play a crucial role in contributing to sustainability goals by improving asset efficiency and minimising the need for travel to worksites. In brownfield engineering scenarios, the integration of 3D scan data into digital twins supports various use cases such as maintenance planning and workforce training, effectively reducing travel costs and carbon footprints.
  • Cost and resource efficiency: Digital twins require cloud systems and IoT solutions, resulting in reduced costs and optimised IT resources. Cloud services facilitate faster, and more efficient data transmission compared to conventional methods, supporting seamless communication between the physical entity and its digital replica.
  • Enhanced decision-making through visualisation: The combination of 3D models and laser scanning enhances decision-making by providing a true digital replica of the existing infrastructure. This accessibility to real-time information aids in better decision-making, change management, and risk mitigation strategies.
  • Final thoughts As sectors aspire for sustainability and nations strive to become global manufacturing hubs, the convergence of current technology and digital twin solutions emerges as a powerful force. The digital twin market's continued expansion demonstrates its transformational potential. Adopting digital twins is not an option for engineers; it is a strategic need. When it comes to navigating the intricacies of today's manufacturing scene, digital twins are a ray of hope, directing engineers toward more effective decision-making, collaborative innovation, streamlined budgeting, and a more sustainable future. The convergence of modern technologies and digital twins is more than just a technological achievement; it represents a paradigm change toward engineering that is wiser, greener, and more responsible for future generations. This holistic strategy, which integrates digital twins with modern technology, promises a future in which engineering is not only sustainable, but also intelligent and responsive to society's changing requirements.

    About the Author


    Avi Dahiya is the founder & CEO of Twyn. As a DeepTech
     futurist and technology evangelist, Dahiya has explored the uncharted territories of technology. His astute insights into evolving technology trends led to the launch of the world’s first Phygital Twin DeepTech enterprise SaaS startup Twyn in 2021, a truly ‘Made in India’ Digital Twin platform to enable Large Manufacturers and OEMs for Smart Manufacturing. He was also recognised as one of the Youngest Business Leaders in the '40 Under 40 Leaders List 2023 by The Times Group.

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