ABB’s Oiartzun Plant: A New Zero-Emission Benchmark

ABB has successfully transformed its Oiartzun factory into its first Spanish site to attain zero operational emissions, part of ABB's worldwide Mission to Zero programme.

The facility, which has been operational for 110 years and specialises in producing wiring accessories and smart home solutions, now provides a blueprint for industrial decarbonisation and cleaner manufacturing processes in the region.

This development could show how established manufacturing sites can be retrofitted to meet modern sustainability standards, a key consideration for executives managing legacy infrastructure.

The Oiartzun site has transitioned to operate on 100% renewable electricity. This is achieved through a combination of on-site generation and the procurement of certified renewable energy sources, completely removing fossil fuels from its operational footprint.

A large investment in photovoltaic capacity now sees more than 580kWp supporting the factory's energy needs. Furthermore, ABB has integrated EV charging infrastructure to support ABB’s transition to an electrified vehicle fleet.

Advancing decarbonisation efforts

The transformation of the Oiartzun site is a tangible result of ABB's commitment to sustainable operations. Mike Mustapha, President of ABB Electrification’s Smart Buildings Division, explained how this achievement fits into ABB’s broader goals.

“Achieving zero operational emissions at our Oiartzun site marks another important step on ABB’s Mission to Zero journey,” Mike says.

“As our first facility in Spain to reach this milestone and one of many sites worldwide advancing toward the same goal, it shows how we are turning ambition into action: electrifying our operations, embedding circular design and using digital energy management to make decarbonisation real. Through this progress, we aim to set a benchmark for sustainable manufacturing and help customers accelerate their own transition to net zero.”

Integrating energy reduction and circularity

Since 2019, the Oiartzun factory has made substantial progress in efficiency. According to ABB, the site has cut its energy consumption by 42%.

This reduction is the result of a clear roadmap that prioritises electrification, automation, heat recovery from machinery and the optimisation of manufacturing processes.

The implementation of ABB’s own building automation and energy management technologies allows for the optimisation of lighting, heating and power distribution. Real-time performance monitoring is handled by ABB eLink, a system designed to improve performance and enable quicker operational adjustments.

Beyond decarbonisation, the factory has also improved its approach to resource efficiency and circularity. It holds an ISO 50001 certification for its energy management system and has also achieved Zero Waste to Landfill status.

Product design follows ABB’s EcoSolutions framework, ensuring that products meet specific environmental standards. This includes wiring accessories that utilise up to 95% recycled materials in their painted finishes and switch inserts that are 100% recyclable.

Fostering collaborative and community partnerships

The success of the Oiartzun factory's sustainability strategy is not solely based on internal changes. The facility actively collaborates with technology centres, suppliers and various circular economy forums.

These partnerships help to foster continuous improvement and ensure the factory remains aligned with evolving market and regulatory expectations. This external engagement model could offer a template for other manufacturing leaders looking to build a robust sustainability ecosystem.

The factory's commitment also extends to the local community. Through an employee-led initiative called Aukerak Sortzen, which translates to "Creating Opportunities", staff participate in projects that benefit the surrounding area.

These activities include beach clean-ups, blood donation drives and programmes that promote local food and the Basque language, demonstrating a holistic approach to corporate responsibility that integrates industrial objectives with community well-being.