How J&J, Suntory, and Toyota Are Cutting Industrial Heat Emissions

Industrial heat applications account for an estimated 9 to 20 percent of global greenhouse gas emissions, depending on the region. Reducing these emissions typically requires deep facility retrofits and close collaboration with process engineers. Johnson & Johnson (J&J), Suntory, Toyota, and Oatly shared their experiences in this area at the GreenBiz 26 conference in February.

J&J's Carbon Relief Fund Model

J&J has allocated up to $40 million annually since 2005 to a carbon dioxide "relief fund" that has financed hundreds of efficiency and retrofit projects across its facilities. One notable outcome is a geothermal plant commissioned in 2023 at a manufacturing site in Belgium, which cut heating and cooling emissions by approximately 30 percent.

A key condition for accessing the fund is that projects must also demonstrate a financial return. J&J reported that as of 2023, the average internal rate of return on these investments stood at 17 percent. The company's science-based target calls for a 46 percent reduction in Scope 1 and Scope 2 emissions by 2030 against a 2021 baseline. As of 2023, it had achieved a 23 percent reduction.

Engaging Engineers Is Essential

The bulk of Scope 1 emissions at all four companies stems from natural gas used in manufacturing processes. J&J uses hot water and steam to power chemical reactions, Oatly to sanitize food processing equipment, Suntory to distill spirits, and Toyota to cure automotive paint. Most of these processes operate below 200 degrees Celsius.

Companies generally pursue a two-track strategy: reducing natural gas consumption at existing sites while influencing sustainability decisions during the design phase of new facilities. However, financial realities can be constraining — replacing a boiler that is only 10 years old is difficult to justify economically.

Toyota's experience illustrates this challenge. The company evaluated a solar thermal system for its paint line at one plant. The return on investment was sound and the available space was sufficient, but the need for 1,000 feet of insulated piping essentially tripled the project cost. Toyota's sustainability team is currently managing a pipeline of 15 near-term projects aimed at reducing natural gas consumption, prioritizing investments that can pay back within two years.

Making the Most of Waste Heat

One of the fastest ways to reduce natural gas consumption is recovering excess steam or hot water from production processes and reusing it elsewhere. This is the first step J&J takes in every decarbonization initiative.

Suntory took a different approach. At its whiskey distillery in Boston, Kentucky, the company launched a project to reduce agricultural waste by converting spent stillage into biogas through anaerobic digesters. This boosted production capacity by 50 percent while also providing fertilizer to local farmers. Due to natural gas supply constraints, the capacity expansion would not have been possible without this project.

Source:

Clancy, H. (March 11, 2026). "How J&J, Suntory and Toyota cut industrial heat emissions." Trellis.

Link: https://trellis.net/article/how-jj-suntory-and-toyota-cut-industrial-heat-emissions/