10 December, London: Thirteen projects awarded a combined £7 million in grant funding have demonstrated industrial advancements in a range of industrial settings, including: metalworking, food equipment cleaning, brewing heat recovery, in-situ road resurfacing and recycling textiles and plastics.
Funded by the Department for Energy Security and Net Zero under its Net Zero Innovation Portfolio (NZIP), the third and fourth phases of the IEEA were delivered by the Carbon Trust in partnership with Jacobs and Innovate UK Business Connect.
According to the results published by the Carbon Trust, the projects have demonstrated innovative solutions to increase resource and energy efficiency in the UK’s industrial sector, with the potential to save 4 million tonnes of carbon dioxide equivalent over 10 years. That is the equivalent of the annual CO2 emissions (2023 data) from the UK’s largest gas fired power station.
These projects showcased the potential for new innovative technologies to reduce energy and resource use in industry — the third largest emitting sector in the UK — which currently accounts for the equivalent of around 48 million tonnes of CO2 per year.
Lord Vallance, Minister for Science, Innovation, Research and Nuclear said:
“The UK is leading the way in industrial innovation to cut emissions and boost productivity across the UK. Programmes like this have allowed us to back new technologies that will help a wide range of businesses, from food to construction.
“This is a great example of how government and industry are working in tandem to deliver real-world solutions to tackle the climate crisis and back industry on the journey to Net Zero."
Paul McKinney, Associate Director at the Carbon Trust and programme manager of the IEEA said:
“I have been proud to be part of the IEEA since the start and to manage the programme over the last six years. The sheer range of sectors covered, from food and chemicals to metals and construction, and the variety of technologies demonstrated from efficient plant cleaning and heat recovery to advanced sensors, AI and robotics clearly shows that there is no shortage of resource and energy efficiency technologies being developed to help industry on its Net Zero journey.
“Many of these technologies bring step-change energy savings to industrial processes, and often provide quality, productivity and other benefits as well as carbon savings. I very much look forward to seeing wide deployment of the technologies we have supported.”
The IEEA funds industrial-scale demonstrations of novel technologies with the potential to reduce energy consumption, maximise resource efficiency and cut carbon emissions. Across all four phases, over £28m in public and private match funding has been invested across 30 IEEA projects since 2018. Grant contributions have been between £130,000 and £1 million, typically providing around 40-60% funding, with the remainder funded by the projects themselves.
The demonstration projects included:
- Project Plan B in partnership with the Salvation Army: A system that has processed over 182,000 kg of textile waste by converting post-industrial polyester waste into high-quality recycled polyester (rPET) pellets. This shows the potential for a viable UK-based fibre-to-fibre textile recycling solution. The project has demonstrated innovative thermo-mechanical extrusion recycling technology to tackle textile waste sourced from donation centres and industrial waste streams and produce processed polyester pellets that retain much of the original material's integrity, making them suitable for textiles and rigid plastics. In enhancing recycling capacity, Project Plan B hopes to accelerate the shift towards a circular textile economy and the promotion of sustainable product design.
- Luxus' Odour Control Accelerator: this project has significantly reduced odour and volatile organic compounds (VOCs) in recycled polymers through large-scale production of Odour-Extraction (ODEX) compound. Odours, and the volatile organic compounds responsible for them, are one of the largest barriers to using recycled polymer, particularly in post-consumer waste (PCW). Through the Odour Control Accelerator, odours have been reduced to undetectable levels allowing the volume of recycled material used in products to increase, reducing the requirement for virgin polymers and saving over 1,200 kg CO2e per tonne. This is especially beneficial with future regulations pushing for an increase in closed-loop recycling.
- APRIL™ Robotics Cooking Cell: developed by OAL, APRIL™ Robotics Cooking Cell is a robotic food processing system that fully automates soup and sauce cooking operations, designed and developed to adapt to individual customer requirements. It uses OAL’s innovative Steam Infusion technology which reduces energy use for cooking and cleaning, requires less cleaning water and improved product yield from 90 to 98% in trials. Carbon savings of up to 75% were demonstrated through the IEEA project.
- 4T2 Sensors has developed a sensor-detection technology to optimise the cleaning of process pipework in the drinks industry, reducing water, energy and chemical use. Demonstrated at Diageo’s Leven site which bottles some of the world’s most famous spirit brands, it uses real-time monitoring of fluid properties to replace time-based cleaning cycles. Roll-out across the site could save 1.5 million litres of water, along with energy reductions and improved production uptime. 4T2’s sensor technology has recently been licensed to the world’s largest Clean-In-Place (CIP) system and chemical supplier, which is expected to lead to widespread adoption.
What’s next
The IEEA was a unique opportunity for UK technology developers to bring their innovations to market, and to prove their technology works at scale in a production environment and the technology providers have gone on to raise over £40m of private finance.
It has shown that innovative energy and resource efficient technologies can provide a significant boost to UK industry’s transition to Net Zero. The projects have comprised installation and demonstration of new technologies in live production environments, with many leading to step change efficiency improvements of up to 70% in some cases.
The technology developers supported by the IEEA are now focused on scaling their solutions, expanding into new markets, and demonstrating real-world benefits. As regulations tighten and demand for sustainable practices grows, these projects have shown that industry will benefit by actively engaging with new technology, piloting new applications, and investing in collaborative efforts to accelerate adoption and drive sector-wide change. Case studies with further details of the technologies and the demonstration results can be found on the IEEA website.
Jake Norman, Managing Director at OAL said:
“This project has shown how advanced robotics can transform core processes like soup and sauce production, improving energy efficiency, reducing waste and increasing yield. Through the IEEA programme, we've gained valuable insight into the carbon footprint of food manufacturing and a clear pathway for scalable, intelligent automation across the sector.”
Sam Scutt, COO at 4T2 Sensors said:
“Participating in the IEEA programme enabled us to demonstrate how real-time fluid monitoring using electrical impedance spectroscopy can transform Clean-In-Place processes, saving water and boosting production. The support from IEEA was instrumental in validating our technology and accelerating its path to commercial deployment across multiple sectors"
Braydon Koss, Sustainability & Project Lead at Luxus Ltd said:
“We were excited to be part of the IEEA. This new technology will aid in developing high quality polymer grades to be used within multiple industries allowing for an increased volume of PCW used in products, not only reducing the need for virgin polymer, but decreasing carbon emissions and helping companies meet the upcoming regulations for sustainability.”
David Ogden, Executive Director Asset and Maintenance at Colas said:
“We were delighted to bring a new in-situ recycling technique to the UK, breaking the mould and helping the sector deliver its collective decarbonisation targets. It was great to collaborate with our clients and industry stakeholders, as part of the IEEA, to introduce this exciting new process and learn together how different solutions can be demonstrated, adopted and scaled within the UK Highways sector.”
Notes to editors
For further information please contact:
The Carbon Trust press office on +44 (0)20 7170 7050 or press@carbontrust.com.
4 million tonnes CO2 saving has been calculated by assuming that each project is successfully replicated at a realistic number of sites over the next ten years with gradually increasing uptake. It is based on the % energy and carbon savings achieved in the demonstration projects applied to the target process at a typical UK site. The number of potential replication sites was estimated by the project lead organisations and moderated for consistency by the Carbon Trust. The savings don’t take into account significant changes in the market, forecast changes in emissions factors (kWh/kg CO2), or the introduction of competing alternative technologies.
List of the remaining 9 projects supported through Phases Three and Four of the IEEA:
| Technology developer | Industrial and research partners | Description |
| Aibuild | The Weir Group | Replacing conventional wooden casting patterns for digitally enabled 3D-printed versions to reduce energy, waste and material use. The Weir Group, supported by the Manufacturing Technology Centre, implemented a Large Format Additive Manufacturing (LFAM) cell using AiBuild’s AiSync software to produce 3D-printed polymer foundry patterns. This transition from wooden patterns has reduced material use, energy consumption, and lead times, while enabling closed-loop recycling. Key results include a 95% reduction in environmental impact, with a 43% reduction in waste materials and a more streamlined pattern-making process. Critically, the process has also allowed pattern designs to be optimised to enable castings with 17% less metal, bringing significant carbon savings from the casting process. |
| Colas | Coventry City Council and Cheshire West and Chester Council | Recycol — an emulsion-based, cold-applied, in-situ road recycling process that reduces carbon emissions by 55% across the value chain when used over traditional hot mix asphalt techniques. Demonstrated by Colas in partnership with Coventry City Council and Cheshire West and Chester Council, Recycol recycles existing road material using a novel cold, in-situ reconstruction technique. This process delivers a flexible, high visco-elastic asphalt and removes the need for new stone to be quarried, processed and moved to site, resulting in significant transport savings, an 89% reduction in virgin resources and a 67% reduction in energy required. |
| FP McCann | B9 Solutions, the National Composites Centre, and Queen’s University Belfast | Dispersed, non-metallic fibre technology for reinforcing precast concrete, to save energy use in manufacturing and improve productivity. FP McCann, in collaboration with B9 Solutions, the National Composites Centre, and Queen’s University Belfast have demonstrated the use of non-corroding basalt fibre reinforced polymer (BFRP) macro fibres in precast concrete applications as a partial replacement for conventional steel reinforcement. This has improved energy efficiency and productivity, lowering the carbon footprint and hopes to enhance the service life of precast elements. The project achieved significant steel reductions in reinforced elements, including a 46% reduction in single-cage pipes and a 37% reduction in double-cage pipes. The use of BFRP macro fibres led to a 14-20% reduction in production energy and a 7-24% lower carbon footprint. |
| Futraheat | Hepworth Brewery | An innovative High Temperature Heat Pump (HTHP) waste heat recovery system at a brewery to recycle heat within the wort boiling process reducing energy consumption by up to 80%. Futraheat has successfully demonstrated the UK's first industrial-scale steam-generating heat pump at Hepworth Brewery, using TurboClaw® technology to capture and upgrade waste heat from the brewing process, reducing energy consumption by up to 80%. The Greensteam High Temperature Heat Pump seamlessly integrates into operations without affecting product quality, directly addressing the need for economically viable electrification of steam driven processes. The technology’s modular design and scalability bring widespread adoption potential across many industries. Futraheat now plans to scale up the system to 1.5 MWt capacity to accommodate a wide range of industrial processes. |
| Haskoning | United Utilities Water Limited | Ephyra® technology to increase biogas yields in Anaerobic Digestion Sewage sludges are usually treated using anaerobic digestion (AD) which recovers energy in the form of biogas. Haskoning patented Ephyra technology is a plug-flow AD process with several digesters operating in series with a recirculation loop, instead of a single stage treatment. This results in increased biogas production, improved process efficiency and a reduction in downstream methane release. The demonstration will complete in Q1 2026 and is expected to achieve 20% more biogas, and significantly increased efficiency and throughput. |
| PyroGenesys | Davidsons Animal Feeds, University of Edinburgh and Aston University | Biomass technology to convert waste grain from the drinks and forestry industries into heat and bio-oil. The Brewers Spent Grain Energy Efficiency Accelerator project tested brewers spent grain (BSG) as a pyrolysis feedstock for renewable heat and biochar production, along with other feedstocks like forestry waste woodchip, whisky draff, and bioethanol plant residues. Whilst the demonstration achieved limited run hours, a techno-economic analysis indicated that a scaled-up PYROCHEMY® system could replace a gas-fired steam boiler with a <5-year payback. Sectors that may benefit include animal feed, breweries, waste wood processing, and wastewater treatment. |
| R&B Industrial | Inktech Ltd and University of Exeter | SmartAIR+ technology to optimise the energy efficiency of local exhaust ventilation (LEV) systems R&B Industrial have developed their wireless SmartAIR+ technology, which uses venturi flow sensors, modulating airflow controllers, and central control algorithms to further optimise fan speed and airflow in industrial ventilation systems. LEV is essential in many industries where there is a risk of exposure to harmful vapours, gases, fumes, dust, mists, and/or microorganisms. The innovative technology uses energy harvesting to draw power from the airstream to fully power the airflow controllers, making the system truly wireless. The IEEA project progressed to in-house testing, and R&B now plan to install a demonstration at Inktech over the next year, along with seeking ATEX certification for use in potentially explosive environments. |
| Stoli Chem | Robinson Brothers Limited | Improving the efficiency of chemical manufacturing processes through a novel chemical reactor that converts from conventional batch processing into continuous flow. Stoli Chem's flow chemistry technology, demonstrated at Robinson Brothers Limited with input from Newcastle University, significantly reduces energy and material consumption in multi-tonne chemical manufacturing. Replacing batch reactors with a continuous flow process improves yield, reduces solvent use, and minimises cooling needs. For a 1,000 kg/year flavouring process, it increased yield by 73%, halved waste, and cut energy use 100-fold. For a 1,000,000 kg/year rubber accelerator process, it reduced energy consumption by 54% and material use by 33%, potentially saving 130,000 kg/ CO2 annually. This scalable technology is applicable across the chemical manufacturing industry. |
| University of Warwick | n/a | Near-Solidus Forging process to reduce the number of hammer strikes needed when forging a near net shape, saving energy and raw material. This project has demonstrated enhanced energy efficiency in the forging industry by improving material utilisation, streamlining processes, and modernising technology. A pilot-scale facility at the University of Warwick demonstrated significant efficiencies through reduced compressed air consumption, minimised material waste, and modernised furnace operations. These advancements have resulted in approximately 95% overall energy savings and nearly two tonnes of CO2e emissions reduction per tonne of processed material. |
About the IEEA
The IEEA programme supports the development of innovative technologies that will help industry reduce energy consumption, maximise resource efficiency and cut carbon emissions. It focuses on innovations with large potential cross-sector energy and carbon reduction impact.
Over £28 million in public and private funding has been committed to developing solutions through partnerships between technology developers and industrial companies willing to test technologies on-site. The IEEA is funded by the UK Department for Energy Security and Net Zero. Phases 3 and 4 are funded through the Net Zero Innovation Portfolio, with Phase 1 and 2 funded under the Energy Innovation Programme. The IEEA is managed by the Carbon Trust, with support from Jacobs and Innovate UK Business Connect.
About the Carbon Trust
The Carbon Trust is a global climate consultancy driven by the mission to accelerate the move to a decarbonised future. We have been climate pioneers for over 20 years, partnering with businesses, governments and financial institutions to drive positive climate action. From strategic planning and target setting to activation and communication - we turn ambition into impact. To date, our 400 experts have helped set 200+ science-based targets and guided 3,000+ organisations and cities across five continents on their route to Net Zero.
About the Department for Energy Security and Net Zero
The Department for Energy Security and Net Zero provides dedicated leadership focused on delivering security of energy supply, ensuring properly functioning markets, greater energy efficiency and seizing the opportunities of net zero to lead the world in new green industries.
The IEEA is part of the Department’s £1 billion Net Zero Innovation Portfolio which provides funding for low-carbon technologies and systems and aimed to decrease the costs of decarbonisation, helping enable the UK to end its contribution to climate change.
