Servo Energy-Saving Technological Transformation & Low-Carbon Green Factory Upgrade

Enterprise V2 is a large-scale precision stamping processing enterprise focusing on new energy vehicle lightweight parts and household appliance metal components, with more than 50 sets of traditional mechanical and hydraulic punch presses in long-term operation. For a long time, the enterprise’s old equipment had prominent problems such as high no-load energy consumption, low forming efficiency, loud noise and hydraulic oil leakage. The high unit energy consumption not only brought high power cost pressure, but also caused the enterprise to fail to pass the green factory audit of many downstream customers, restricting the expansion of high-end low-carbon orders.

Starting from the second half of 2025, Enterprise V2 launched a full-staff low-carbon green transformation project, focusing on eliminating high-energy-consumption old equipment, fully replacing it with high-efficiency servo intelligent punch presses, and supporting green management upgrades such as workshop environmental protection renovation and energy consumption digital monitoring. After half a year of phased transformation, the enterprise achieved substantial reduction in power consumption, zero hydraulic pollution, and full compliance of environmental protection indicators, successfully obtaining national green workshop certification and high-end customer low-carbon supplier qualification, becoming a typical benchmark for energy-saving and carbon reduction transformation in the domestic stamping industry.

Before the servo energy-saving transformation, Enterprise V2’s problems are typical common pain points of traditional old stamping factories:

Traditional mechanical punch presses maintain fixed-speed operation all the time during working hours, with no-load idle energy consumption accounting for 40% of the total power consumption. Even in mold adjustment and waiting state, the equipment still consumes power continuously, resulting in huge invalid power waste and high annual electricity cost.

Hydraulic equipment has frequent oil leakage problems, resulting in workshop ground pollution and part surface oil contamination. The enterprise needs to replace a large amount of hydraulic oil every year, with high material consumption cost and environmental protection hidden dangers, failing to meet clean production standards.

Old mechanical equipment has violent vibration and loud operating noise, with on-site noise exceeding 89dB for a long time, which not only affects employee occupational health, but also fails to meet the environmental protection assessment requirements of green factories.

Downstream new energy and vehicle enterprises have strict carbon emission and energy consumption assessment requirements for suppliers. The enterprise’s high unit product energy consumption leads to repeated failures in green audits, missing a large number of high-value low-carbon orders.

Traditional equipment has unstable pressure output and poor slider motion accuracy, resulting in low product forming consistency, high defective rate, and additional material and energy waste caused by rework and scrap.

Aiming at high energy consumption, pollution and unqualified green indicators, Enterprise V2 implemented three core green transformation measures to build a full-link low-carbon stamping production system:

The enterprise completely eliminated 32 sets of outdated mechanical and hydraulic punch presses with high energy consumption and low efficiency, and newly deployed 30 sets of high-precision servo direct-drive intelligent punch presses. The new equipment supports intelligent speed regulation, pressure adaptive adjustment and automatic idle stop, realizing precise energy output according to processing procedures and completely eliminating no-load power waste.

Thoroughly solve the hydraulic oil pollution problem, realize full workshop non-hydraulic clean production. Optimize workshop shock absorption and noise reduction facilities, install professional noise isolation and ventilation equipment, reduce production noise and dust, and fully meet occupational health and environmental protection emission standards.

Install intelligent electric energy meters and equipment operation monitoring terminals for all servo production lines, realize real-time statistics, analysis and early warning of single equipment and single product energy consumption data. Establish a daily energy consumption assessment mechanism, optimize production scheduling and process parameters, and continuously reduce unit product carbon emissions.

After the completion of the green energy-saving transformation, Enterprise V2 has achieved comprehensive breakthroughs in energy consumption reduction, environmental protection compliance, cost control and market qualification. All indicators have reached the industry leading green factory level, with strong industry promotion value.

In terms of comprehensive operational benefits, the servo green transformation has brought dual value of policy compliance and economic profit to Enterprise V2. The enterprise’s annual electricity cost is reduced by 1.46 million RMB, and the annual maintenance and hydraulic material consumption cost is saved by 660,000 RMB, with a total annual energy-saving benefit of 2.12 million RMB. At the same time, it successfully passed the national green workshop certification and the low-carbon supplier audit of many new energy head enterprises, newly increasing 30% of high-end low-carbon orders, realizing the simultaneous improvement of environmental benefits, customer structure and economic benefits.

This servo energy-saving and low-carbon green transformation case is completely different from digital intelligence, talent training, supply chain optimization, safety management and lean management cases. It focuses onequipment energy efficiency upgrading and green qualification empowerment, providing a replicable low-carbon transformation path for traditional old stamping enterprises:

Many traditional enterprises regard green transformation as cost burden. In fact, servo equipment energy-saving transformation can reduce electricity costs in the short term, obtain green supplier qualifications in the medium term, and seize high-end low-carbon market dividends in the long term, which is a high-return strategic investment.

The core problems of traditional stamping factories such as high energy consumption, oil pollution and loud noise come from backward equipment. The full replacement of servo intelligent equipment can fundamentally solve environmental protection hidden dangers and energy waste, and synchronously improve production precision and yield.

In the context of dual-carbon strategy, downstream high-end customers have fully incorporated carbon footprint and energy consumption indicators into supplier assessment. Only by completing green and low-carbon transformation can enterprises get rid of low-end homogeneous competition and enter the high-value industrial supply chain.

In the future, Enterprise V2 will further build a full-life cycle carbon asset management system, carry out carbon inventory accounting and carbon neutrality workshop construction, and realize intelligent energy-saving scheduling of production lines. For the entire punch press stamping industry, servo energy-saving intelligence and green low-carbon production will become the basic threshold for enterprise survival and development. The industry will accelerate the elimination of backward high-energy-consumption equipment, continuously improve industrial energy efficiency level, and promote China’s precision stamping manufacturing industry to develop in a high-efficiency, low-carbon and high-quality direction.