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In order for Australia to reach its goal of net zero by 2050, it needs the help of its manufacturing sector, which accounts for 10% of the nation’s carbon emissions. And the sector is pulling its weight, the Western Sydney Manufacturers Forum heard recently — developing ‘green concrete’, carbon-tracking sensors and technology which can minimise carbon emissions during beer fermentation.

More than 30 experts from universities, industry and government described multiple ways sustainability can deliver real-world impact, cost savings and market differentiation for manufacturers. The forum heard many examples, including an opportunity to reduce emissions from concrete production — which contributes around 8% of global carbon emissions, or more than aviation and shipping combined.

Professor Olivia Mirza from Western Sydney University described the initial pushback to the use of ‘green concrete’ — an eco-friendly alternative which is produced using waste materials — in the Parramatta Light Rail project.

“The initial cost for building [the light rail using green concrete] was let’s say 10 or 12% higher, but then if you do the cost-benefit analysis — less maintenance — it ended up saving 25%,” Mirza said.

The forum highlighted the importance of clear communication and education, suggesting the use of modern formats like social media platform TikTok to effectively engage different stakeholders, especially in the trades, around decarbonisation in building materials.

The aim of the event — hosted by the NSW Smart Sensing Network and the NSW Decarbonisation Innovation Hub at Penrith Panthers — was to showcase opportunities and help manufacturers and their supply chain navigate new emissions reporting requirements.

Dr Martin Ams, a product engineer at Macquarie University, said innovative optical fibre sensors are helping utilities like Sydney Water contribute to net zero by predicting concrete corrosion in wastewater infrastructure.

“Over time, concrete can actually capture and remove CO2 directly from the atmosphere through a process known as carbonation,” he said. “If you have concrete structures that are absorbing CO2 from your atmosphere, you want them to last long so you can keep absorbing this CO2.”

Dr Victor Hernandez Moreno from the UTS Centre for Advanced Manufacturing described how advanced automation and ‘digital twin’ technology can drive more sustainable production decisions for manufacturers. His team operates two mirrored beer-brewing facilities — in Sydney and Germany — that share a unified digital twin, allowing them to analyse data, enhance product quality and reduce carbon emissions.

Keynote speaker and Climate Change Authority Chair Matt Kean said advanced manufacturing in Western Sydney is poised to lead Australia’s decarbonisation efforts by electrifying industrial processes, improving energy efficiency and producing green materials like hydrogen.

“The [Authority’s] Sector Pathways Review revealed that Australia has a great shot at crafting the products, goods and services that will be in high demand,” Kean said. “As the world shifts to net zero, we must be prepared to back our entrepreneurs and innovators and remove policy and regulatory barriers that inhibit progress.”

Kean said products like renewable hydrogen, green ammonia and green metals were essential to reimagining Australian industry. “Importantly, they’re going to be in hot demand, not just domestically, but right across the globe.”

NSW Net Zero Commission principal advisor Manuel Weirich said there is lots of opportunity to reduce emissions in light industry such as manufacturers and smaller processors, which emit 45% of NSW industry emissions.

“These emissions come from things like burning gas in boilers, from engines and motors, chemical processes, calcination in bricks or in cement, and lots of other things,” Weirich said. “Some of the processes are difficult to decarbonise, but others already have solutions available … including heat pumps for water heating, electric forklifts, and better energy efficiency.  

“Manufacturing has a big role to play, to produce the clean materials, the low-emissions materials, and the products and machinery that other sectors use to decarbonise themselves.”

NSW Chief Scientist Hugh Durrant-Whyte said with investment in R&D, skills, digitisation and real-time data, and by preparing for mandatory reporting, Australia can build resilient supply chains and drive sustainable, high-value growth across all business sectors. 

“Digitisation will help identify gaps, improve performance and address skill shortages — especially in hard-to-abate industries,” Durrant-Whyte said. “Achieving net zero will benefit everyone. Small businesses can cut energy costs and preserve expertise through digitisation. Medium businesses can scale up and strengthen supply chains. Large corporations will streamline compliance, meet stakeholder expectations and drive sustainable growth.”

The Executive Director of the Advanced Manufacturing Readiness Facility (AMRF), Ben Kitcher, described how his organisation helps manufacturers adopt technologies that help them become profitable and sustainable.

“What we’re discovering is there is this mutual objective around decarbonisation which always leads back to productivity and profitability,” Kitcher said.

The forum heard that while digital literacy is strong among younger generations, manufacturing still suffers from outdated perceptions. It heard how SMEs in Western Sydney can stay competitive by embracing digital transformation, sustainability and circular economy principles. SMEs are also facing ongoing challenges in resourcing innovation and workforce development, but programs like CSIRO’s Generation STEM are stepping in with practical support through paid internships and university and industry talent matching.

“We have a lot of SMEs that come to us and say their challenge is recruitment and retention, but sometimes we’ve got some SMEs that come to us and say they don’t have the time to do this piece of work,” Generation STEM team leader Luana Caro said.

Chovil & Thake sustainability marketing specialist Hannah Welch said 45% of Australians always or often consider sustainability as part of their purchasing decision-making. She said manufacturers can leverage environmental, social and governance (ESG) data not just for compliance, but as a strategic marketing tool to attract investors and recruit staff.

Andrew Bedrossian, Manager of Renewable Manufacturing at the NSW Department of Climate Change, Energy, the Environment and Water (DCCEEW), said the Net Zero Manufacturing Initiative supports clean technology innovation and low-carbon product manufacturing, with particular focus on revitalising local solar manufacturing. He said there is growing industry appetite and significant investment interest, especially from Western Sydney manufacturers, pointing to strong potential for scale-up and impact.

“We have the world-leading IP here with some of the best brains in the business when it comes to solar,” Bedrosian said. “All the commercial windfalls are offshore. We don’t have anything here, and that’s a real shame. How can we change that?”

Image caption: Climate Change Authority Chair Matt Kean delivered the keynote speech at the Western Sydney Manufacturers Forum. Image credit: AM Visuals.