Bodycote reaches zero-emissions target at two plants

Bodycote has marked a major milestone in its sustainability journey, defying the recent trend of ‘green-hushing’ and demonstrating that ambitious 2030 decarbonisation targets are not only achievable but increasingly demanded by customers. The company, recognised globally as a leading provider of precision heat treatment and specialist thermal processing services, has confirmed that two of its UK facilities — Derby and Rotherham — are now operating with zero carbon emissions.

These sites, which specialise in heat-treating turbine blades for Rolls-Royce jet engines, are believed to be the first in the sector to reach this level of decarbonisation. Both plants are now fully electric, powered entirely by renewable energy sources, and consume no fossil fuels. Crucially, this achievement has been realised without resorting to carbon offsetting.

Operating within a global heat treatment industry valued at between $25–30 billion, Bodycote’s work is energy-intensive but vital. Its processes underpin the safety, durability and performance of products that are central to modern life. Without Bodycote’s expertise, aircraft engines wouldn’t survive a single flight, car gearboxes would fail within days, and surgical tools or joint replacements would fall short of essential safety standards.

Jim Fairbairn, CEO of Bodycote, emphasising the growing importance of sustainability to customers, said: “Our customers, many with ambitious 2030 targets, are looking for suppliers who can support their decarbonisation efforts. Recently, a customer with a 90% carbon reduction goal came to us because of the impact offered by our lower-carbon thermal processing. These are real demands, and the clock is ticking. For Bodycote, leading in this space is not only the right thing for the planet, but also the right thing for our global business. As well as the progress made in Derby and Rotherham, we are running pilot decarbonisation projects across Europe and North America.”

Industrial heat electrification
Bodycote’s transition supports the UK Government’s Industrial Decarbonisation Strategy and has been driven by investment in industrial heat electrification, energy efficiency and renewable energy sourcing. At the Derby site, located adjacent to Rolls-Royce, a new closed circuit adiabatic-cooling system has replaced traditional evaporative cooling towers. This innovation has delivered electricity consumption savings of 73%, reduced water use by over 85%, and eliminated the need for chemical dosing and cleaning — while also cutting peak electrical load and associated carbon emissions.

Larissa Lee-Favier, SVP Sustainability at Rolls-Royce, praised the achievement. She said: “We congratulate Bodycote on achieving heat treatment operations with zero emissions. We encourage all our partners and suppliers to take action to make the operations and activities they can influence sustainable. Bodycote’s achievement sets a strong and commendable example for the industry.”

Bodycote is currently the only major heat treatment company with a near-term carbon reduction target verified by the Science Based Targets initiative (SBTi). The Derby and Rotherham facilities now serve as blueprint sites for a wider global decarbonisation programme, with the next zero-emission site expected to be announced shortly.

The transformation also contributes to regional low-carbon manufacturing networks and aligns with national goals to reduce industrial emissions. The Climate Change Committee, which advises Parliament on the UK’s climate adaptation strategy, has identified the electrification of industrial heat as a top priority for meeting future carbon targets.

Energy efficiency
During a recent visit to the Derby site, Baggy Shanker, Derby South MP and a former Rolls-Royce engineer, met with Mr Fairbairn and the team behind the transformation. He said: “It is fantastic to see such a milestone achieved here in Derby. I often hear that achieving zero emissions is too difficult or costly, so it is refreshing to see the drive behind Bodycote’s commitment to reaching this goal at its Derby and Rotherham facilities. It is a shining example of how industry can lead the way in building a sustainable future, setting a precedent for the sector and beyond. Congratulations to everyone at Bodycote for their vision and hard work.”

Energy efficiency
Across its network of more than 100 sites worldwide, Bodycote is rolling out a programme of energy efficiency, electrification and on-site renewable energy projects. Innovations include on-site nitrogen gas generators, novel hydrogen electrolysers, and the sourcing of green methanol for use in processing. The company is also exploring ways to reduce emissions from the supply of process gases traditionally transported by road.

Together, these initiatives will enable Bodycote to offer low or zero-emission heat treatment solutions to a growing number of customers. With sustainability firmly embedded in its strategic agenda, the company has already achieved a 27% reduction in energy intensity and a 29% reduction in associated carbon emissions compared to 2019 levels. It is targeting a 46% reduction in operational emissions by 2030.

Importantly, the transition to zero operational emissions has not resulted in increased customer costs, extended lead times or reduced capacity. The most significant outcome is the measurable reduction in carbon emissions for customers outsourcing their thermal processing. In specific scenarios, emissions have been reduced by up to 60% for comparable treatment approaches.

Mr Fairbairn concluded: “This achievement puts Derby and Rotherham on the map as centres of excellence for decarbonisation. When an energy-intensive industry like heat treatment can show real climate action, it demonstrates that a green future is within reach.”