Adopting a “learn, adapt, and improve” culture for Indian manufacturing

India has a long-standing strength in learning by doing, and what makes this approach even more powerful is the ability to complement it with insights from proven concepts, thus accelerating innovation and scaling impact. Sanjeev Arora, President of Motion Business and IEC Low Voltage Motors at ABB India, believes the country has the ability not just to learn, but to adapt and excel. In this interview, he shares compelling perspectives and initiatives that are shaping ABB’s operations in India.

Could you elaborate on how ABB integrates sustainability into its operational framework, from plant design and energy generation to customer engagement and brand building?

Sustainability is deeply embedded in ABB’s operational framework and business philosophy; it is both a guiding principle and a driver of energy efficiency. Across India, our plants operate with sustainability at its core. For instance, the Faridabad motor manufacturing facility generates 20% of its electricity from in-house solar power, and all our sites are working towards becoming single-use plastic-free. Several of our plants are already water-positive, and half of our factories are certified for Zero Waste to Landfill, with ISO 50001 Energy Management Systems in place.

Our green campus journey is another proud milestone. With our Peenya campus recently receiving the IGBC “Platinum” rating, ABB India has become the first in our sector to achieve 100% IGBC Platinum certification across all manufacturing locations.  On the climate action front, we are aligned with ABB’s global ambition of achieving net-zero emissions by 2030. Using 2019 as a baseline, we have already reduced our greenhouse gas (GHG) emissions in India by more than 87%. This progress is powered by high-efficiency motors across facilities, utility systems equipped with ABB drives, and HVAC systems running on super high-efficiency motors powered by our own technology.

What role does energy efficiency, particularly the upgrade of motor technology, play in advancing both sustainability and market competitiveness for Indian industries?

Energy efficiency is crucial because it represents the easiest initial step. Data indicates that 45 percent of energy consumed in any industry is used by motor-driven equipment. In India, more than 80 percent of the installed base consists of I2 motors, while we already have access to more advanced technologies like IE3, IE4, and now even IE5.

Given that IE2 technology remains the standard, it presents a significant opportunity for improvement. If we replace all these IE2 motors with IE3 or IE4 motors equipped with drives, we could save approximately 20 to 25 percent of our current energy consumption.

I want to emphasise that the energy saved or not consumed is the cleanest energy. By saving energy, we reduce the load and enhance the efficiency of our operations, which benefits sustainability, reduces carbon footprints and makes us competitive. When we operate our plants more efficiently, we become competitive. It truly is a win-win situation for the entire market.

You mentioned the motor standards available in the market, but India has been slow in adopting them. What is your response?

We come from an origin of intent-based action rather than being driven by policy. If the intent is right, the industry will adopt these changes; if not, they have alternatives. The good news is that more than 50% of our production consists of IE3 and IE4 motors, indicating that the industry recognises the benefits of energy efficiency. They have established their own sustainability targets, such as net-zero emissions and net-zero goals, and they are making progress toward these objectives. This trend is one of the catalysts that can drive them forward.

Raising the minimum efficiency standard to IE3 would be beneficial, and we can even aim for IE4, since we already have the technology available in India. When we talk about India’s ambition to become a global leader, energy efficiency will certainly contribute to our sustainability objectives and net-zero vision.

Global vendors and customers are seeking partners who have a strong sustainability focus integrated into their strategy. Operations with sustainability practices and credentials through proper reporting on energy efficiency and sustainability can strengthen our position in the global market. We can have a competitive advantage in global sourcing, which will also support our export efforts.

In the context of India’s role as a global outsourcing hub, cost is a major factor in the open market. How do businesses balance the immediate capital expenditure with the long-term benefits of energy-efficient solutions?

Cost remains a factor in the open market. However, businesses must strike a balance between immediate capital expenditure (CapEx) and the long-term benefits of energy-efficient solutions. One effective approach is to evaluate the total life cycle cost rather than focusing solely on initial expenses. For instance, in the case of energy-efficient, motor-driven systems, businesses can typically achieve a return on investment (ROI) within two to three years. This broader focus on total life cycle cost ultimately delivers more substantial financial benefits over time.

Recognizing the importance of energy efficiency, we aim to unite stakeholders across industries through a dedicated energy efficiency movement. This initiative is committed to advancing energy-efficient solutions, sharing best practices, providing collaborative platforms, and establishing strategic partnerships that showcase the tangible value of energy-efficient projects.

Through these efforts, we address not only the immediate need for energy efficiency but also create a foundation for future innovations across sectors such as transportation, construction, and beyond. By prioritizing sustainable and forward-thinking solutions, we empower businesses to achieve both economic and environmental goals, reinforcing the long-term value of energy-efficient investments.

A significant portion of India’s energy comes from renewable resources, and there is a rapid increase in electrification across sectors like logistics. How do you think this trend will impact the overall energy consumption chain?

India is a growing economy with a solid foundation. Its manufacturing industry is expanding, and every aspect of this industry requires energy. What we need is a good mix of renewable, conventional, and other energy sources. Grid stability and other parameters also require immediate attention. Here, ABB plays a vital role in ensuring grid stability through our synchronous condenser technology, which improves the power factor and provides reactive power back to the system. This ensures that the grid operates in a highly optimised manner.

What has been the market reception for your latest flame-proof motors?

These motors have been a big success because they represent the pinnacle of technology, mirroring the high standards we deliver globally. Our flame-proof motors meet the IP66 standard, and the time between our launch and receiving the first order was less than 15 days, indicating a strong market response. We haven’t just introduced a limited range of motors; we now offer a comprehensive selection that spans frame sizes 80 to 355, and our growth continues to strengthen.