ABB Modernizes Florence, SC Plant To Advance Energy Independence And Boost Productivity

• 47-year-old manufacturing facility joins ABB flagship sustainability program, Mission to Zero, after adding on-site solar power generation that supplies 80% of site’s energy and reduces grid reliance
• Energy productivity increased 74% while adding 10 new product lines and growing revenue 140%, proving sustainability can enhance profitability
• Digital technologies and data-driven insights helped aging facility modernize in a practical and commercially viable way

ABB’s 142,000-square-foot Electrification Service manufacturing facility in Florence, S.C., has reached a significant milestone in its sustainability journey, qualifying as an ABB Mission to Zero site. The 47-year-old facility now sources roughly 80% of its electricity from a three-acre solar array that generates approximately 1.5 million kWh of on-site renewable power annually, helping control energy costs and strengthen operational resilience.

“We saw an opportunity to reduce our environmental impact while simultaneously improving our bottom line and resilience,” said Mateusz Zajac, Sustainability Leader for ABB Electrification Service. “Our Florence facility and its staff prove that sustainability initiatives and profitability can go hand in hand. In fact, these initiatives often enhance profitability while decoupling our growth from grid constraints.”

The site supports highly specialized manufacturing processes requiring precision controls and extended production cycles. Its phased modernization demonstrates how legacy industrial facilities can take practical, incremental steps to improve sustainability and performance without disrupting operations.

Key outcomes include:

• 74% increase in energy productivity: Achieved while adding ten new product lines and increasing revenue by 140%, demonstrating improved energy intensity alongside business growth.
• Zero waste to landfill: The site diverts more than 90% of its operational waste from landfills, leveraging a waste-to-energy program that converts non-recyclable material into usable energy, which complements existing recycling initiatives that divert 100% of cardboard, wood and metals to recycling facilities. These initiatives have set the site on a clear path to zero waste to landfill by the end of 2026.
• $70,000 in projected annual savings: Driven by on-site renewable generation, electrification of facility systems, and expanded waste diversion programs that reduce disposal and energy costs.
• Greater energy resilience: On-site solar supplies approximately 80% of annual electricity demand, reducing exposure to grid disruptions and price volatility.

ABB continues to use digital technology and data to achieve savings and efficiencies. The Florence facility deployed the ABB Ability Nsight energy monitoring platform, which uses more than 20 real-time monitors to precisely identify wasted energy. Additionally, the facility has integrated ABB INTEGRA Supervisory Building Control to further automate and optimize energy-intensive systems.

“Our operations in Florence are a clear example of how older, hardworking industrial facilities can modernize in a practical and commercially smart way. Instead of pursuing full equipment replacements and large-scale renovations that can interrupt production and demand major capital investments, the team focused on targeted upgrades, often supported by data-based insights,” said Zajac. “This approach shows how a facility built for a different era can evolve into one that supports cleaner energy, stronger resilience and better long-term performance.”

The Florence facility is one of the latest to achieve ABB’s Mission to Zero milestone by meeting or exceeding minimum targets in energy efficiency as well as emissions and waste reductions. Through the program, sites combine ABB digital energy and building solutions with renewable energy as part of their journey to reach net-zero operations by 2050.

ABB is a global technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. By connecting its engineering and digitalization expertise, ABB helps industries run at high performance, while becoming more efficient, productive and sustainable so they outperform. At ABB, we call this ‘Engineered to Outrun’. The company has over 140 years of history and around 110,000 employees worldwide. ABB’s shares are listed on the SIX Swiss Exchange (ABBN) and Nasdaq Stockholm (ABB). www.abb.com

ABB Electrification is a global technology leader enabling the efficient and reliable distribution of electricity from source to socket. With more than 50,000 employees across 100 countries, we collaborate with our customers and partners to solve the world’s greatest challenges in electrical distribution and energy management. As the energy transition accelerates and electricity demands grow, we are electrifying the world in a safe, smart and sustainable way. At ABB, we are ‘Engineered to Outrun’, and we are passionate about helping our customers and partners do the same. go.abb/electrification