TAGS:#industrial automation #PLC #DCS #control systems #factory automation #energy efficiency
GSK’s Tuas South Facility Advances Energy Efficiency
GlaxoSmithKline (GSK) has taken a significant step toward net-zero by partnering with ABB to modernize its Tuas South vaccine manufacturing facility in Singapore. Through this initiative, the factory expects to save 615 MWh of electricity and reduce CO₂ emissions by 246 tons annually. In addition, energy costs could drop by up to USD 130,000, surpassing initial decarbonization goals by 25 percent. This move demonstrates how industrial automation, including advanced PLCs and control systems, can drive measurable sustainability results.
IE5 SynRM Motors and VSDs Accelerate Decarbonization
The upgrade features 65 ABB IE5 ultra-premium efficiency synchronous reluctance motors (SynRM) paired with variable speed drives (VSDs). VSDs adjust motor speed to match actual system demand, enhancing energy efficiency by approximately 25 percent. Moreover, these motors are magnet- and rare-earth-free, aligning with circular economy principles. This combination provides reliable, long-term performance while ensuring a strong return on investment within 2.5 years.
Phased Implementation for Maximum Impact
ABB deployed the project in two phases between September and December 2025. Phase one installed 34 motors and HVAC drives, projected to reduce CO₂ emissions by 140 tons annually. Phase two will add 31 more units, contributing an additional 106 tons of annual CO₂ savings. This structured approach ensures minimal disruption to operations while maximizing energy efficiency gains.
Advanced Energy Reporting Enables Measurable Progress
By integrating ABB’s SynRM and VSD technologies with sophisticated energy reporting tools, GSK can monitor and validate energy performance in real time. Consequently, the facility demonstrates tangible progress toward its global goal of reducing greenhouse gas emissions by 80 percent by 2030. This initiative highlights how digitalized factory automation can empower industrial players to achieve ambitious sustainability targets.
Expert Insight: Industry Trends in Industrial Automation
Upgrading motors and drives is a practical strategy for industrial facilities to cut energy use without expanding power generation. As more factories adopt PLC-driven monitoring and DCS-based control systems, companies can achieve precise energy optimization, reduce operational costs, and enhance system reliability. ABB’s project with GSK illustrates how combining industrial automation technology with sustainability goals can deliver measurable environmental and financial benefits.
Application Scenario: Sustainable Pharmaceutical Manufacturing
This case provides a replicable model for pharmaceutical and manufacturing industries. Facilities can implement IE5 SynRM motors with VSDs, conduct fleet-level energy appraisals, and leverage industrial control systems to optimize energy use. By doing so, companies can significantly lower carbon emissions while improving operational efficiency, aligning with global net-zero objectives.