Energy management and industry 4.0: Analysis of the enabling effects of digitalization on the implementation of energy management practices

Enrico Cagno, Davide Accordini, Patrik Thollander, Mariana Andrei, A S M Monjurul Hasan, Sonia Pessina and Andrea Trianni

Applied Energy, 2025, vol. 390, issue C, No S0306261925006075

Abstract: Manufacturing industries face significant challenges in reducing final energy use and improving Energy Management Practices (EnMPs). Industry 4.0 (I4.0) technologies provide transformative opportunities to address these challenges, yet their integration with EnMPs remains underexplored. This study aims to fill this gap by reviewing I4.0 solutions applied in manufacturing and assessing their impact on companies' Energy Management strategies. Specifically, the study develops a Smart Factory framework, categorizes I4.0 technologies into four clusters (system, infrastructure, service, and process) and identifies nine key Areas of Impact. The framework systematically maps these technologies to assess their effects on Energy Management. This model is validated and applied in two Swedish firms manufacturing respectively automotive components and heavy machinery, and machine tool accessories. Results indicate that EnMPs affect multiple areas, while their most notable impact is observed in the area of ‘awareness’, ‘connectivity & integration’, and ‘visualization’. Similarly, I4.0 technologies enhance EnMPs by improving energy monitoring, performance evaluation, and energy-efficient process design. Internet of Things emerged as a critical enabler, facilitating real-time energy data collection and analysis, while Artificial Intelligence and Big Data Analytics provided predictive capabilities to optimize energy use and prevent inefficiencies. Simulation tools and Virtual Reality supported process visualization and design optimization, while Advanced Robotics enhanced flexibility and reduced operational energy waste. Energy-aware production scheduling, predictive maintenance, and the design of energy-efficient systems were the most significantly impacted practices. This framework demonstrates how I4.0 technologies can enable the transition towards smarter, energy-efficient manufacturing, contributing to industrial decarbonization and sustainability goals. By providing actionable insights, the framework equips researchers and practitioners with a systematic approach to integrating digital technologies and energy management strategies, bridging a critical gap in the literature.

Keywords: Energy management; Energy efficiency; Industry 4.0; Smart factory; Digitalization; Manufacturing; Decarbonization (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1016/j.apenergy.2025.125877

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