Solution provider
Danfoss engineers solutions that increase machine productivity, reduce emissions, lower energy consumption, and enable electrification.
Case
Energy efficiency in industry
Circular value chains
Green value chains
+3
Competitive decarbonization in industry: Cutting energy use, emissions, and costs
11 June 2025
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Challenge
In Poland, where over 20% of GDP comes from industry and the energy mix is still dominated by fossil fuels, decarbonising manufacturing is both a challenge and a necessity. Danfoss’ production campus in Grodzisk, near Warsaw, highlights the opportunities for reducing emissions in a cost-effective way across both new and existing industrial facilities.
Solution
The Grodzisk campus comprises three factory halls, with Hall #3 – built in 2021 – designed from the outset for energy efficiency and low emissions. Several key measures enable competitive decarbonization:
- Shutting Off Initiative: Instead of keeping machines on standby, Danfoss tested turning them off when not in use. In Hall #3, this saves 4,607 kWh per day – with no impact on productivity. This low-cost measure is now being scaled across all Danfoss sites.
- Variable Speed Drives (VSDs): Sixteen VSDs regulate air handling units, reducing energy use by up to 40%. The system also supports predictive maintenance, reducing downtime and improving cost control.
- Heat Pumps & Heat Recovery: Hall #3 uses heat pumps (SCOP 3.8) to recover excess heat from production equipment for indoor heating. The reversible heat pumps also support cooling, reducing reliance on fossil fuels for climate control.
Retrofitting measures were also implemented in older buildings not originally designed with CO2 neutrality in mind:
- Upgraded HVAC in Hall #1: In 2023, two new air handling units were installed in just 10 days. These units now recover waste heat from production and ventilation and use it to pre-heat fresh air, reducing gas use. Cooling was also improved, eliminating the need for rented AC units in summer.
Result
Together, these measures show how industrial decarbonisation can be achieved without compromising performance:
- Hall #3 is CO₂-neutral with low operating costs.
- The HVAC upgrade in Hall #1 alone saves 1.8 million kWh and EUR 420,000 annually, with a payback time under 2.5 years.
- When scaled globally, the Shutting Off Initiative could save Danfoss 80 million kWh and EUR 3–5 million per year.
The Grodzisk site now serves as a real-world example for how competitive decarbonisation can be practically applied across industry.
