ESG in Welding Industry

What is ESG :

Environmental, Social and Governance (ESG) is strategic and operational framework that aims to assist organisations of any size and type to implement and report on their activities, products, services, and commitment to support the achievement of sustainable development, social justice,  and good governance. Adopting ESG brings a clear focus on organisations impact on environment and society, including contribution to delivery of United Nations ( UN), Sustainable Developmental Goals ( SDG) as well as evaluating the impacts of environment and
society on organization.

Key Trends In India

India is the third largest emitter of green house gases (GHGs) in the world. It is also a signatory to the Paris Agreement that aims to limit global warming by keeping the global temperature rise in this century well below 2 degrees Celsius above pre-industrial levels. India has committed to reduce the carbon intensity of its economy by more than 45%, to meet 50% of its energy requirement from renewable energy by 2030, and reduce its total projected carbon emission by 1 billion tonnes by 2030 to become carbon neutral by 2070. ESG criteria have become a critical benchmark for evaluating the sustainability and ethical impact of industries worldwide. While traditionally associated sectors like finance, energy and manufacturing, ESG is increasingly relevant in the welding industry given its integral role in infrastructure, construction and manufacturing ecosystem. In both, the global and Indian context, the welding industry faces challenges as well as opportunities to align with ESG goals. This article delves into how “E” i.e, Environmental pillar of ESG, is shaping the future of welding,
the current landscape, and the future road ahead.

Environmental (E) -Reducing the industries footprint.

Global Perspective: Globally, welding operations significantly contributes to GHG emissions, particulate matter and waste production. Common processes such as arc welding consume substantial electricity and release fumes containing hazardous compounds like manganese, chromium, and ozone. Leading companies worldwide are implementing measures for transition to low emission welding technologies, adopting automation & robotic welding systems to enhance precision and reduce material waste, and implementing fume extraction and filtration systems to improve air quality.

Indian Perspective: While large-scale industries are beginning to acknowledge their environmental responsibilities in India, many small and medium enterprises ( SMEs) still lag behind due to a high cost barrier and low awareness. However, government initiatives like “Make-in-India” and green manufacturing policies has resulted in growing pressure on the sector to modernize and adopt cleaner practices. Securities and Exchange Board of India ( SEBI) guidelines for disclosure through Business Responsibilities and Sustainability reporting ( BRSR) on ESG have put lot of focus on ESG initiatives on listed companies. Regulatory bodies i.e., pollution control board, are pushing for cleaner production techniques, waste management protocols, compliance with environmental regulations under the Factory Act and Environmental Act.

Social S: Safety, Health, and Workforce Development

Global Perspective: Welding involves exposure to UV radiation, toxic fumes, and extreme heat, which pose serious health hazards. Globally, companies are investing in Advanced Personal Protection Equipment (PPE), automation to reduce human exposure, extensive safety training and certification, programs promoting diversity, equity, and inclusion in the skilled sector.
Indian Perspective: In India, while  occupational health & safety is legally mandated, enforcement is inconsistent, especially in the unorganized sector. However, with rising regulatory pressure on large companies, including their supply chains, there is gradual positive change being seen. In addition, ‘Skill India’ offers formal certification and opportunities for partnership with global institution to impart advanced training. Further, there is increasing emphasis on worker well being, especially post Covid-19.

Governance (G) -Ethics, compliance, and accountability:

Governance in the welding sector involves ensuring compliance with international standards (ISO, ASME, AWS), ethical sourcing, and transparent supply chains. Companies are integrating third-party audits to track compliance. India is gradually adopting corporate governance reforms. Public and private sector enterprises are publishing Sustainability reports introducing ESG boards or committees. The process of aligning with SEBI’S ESG disclosure, i.e, BRSR for top 1000 listed companies has begun. The welding industry, like many other industries, faces increasing pressure to adopt sustainable practices. The push for greener operations stems not only from regulatory domains but also from growing awareness of environmental responsibilities and consumers’ preference for sustainable products. Globally, during recent years welding industry has made significant strides in embracing sustainability, evolving through technological innovation and a shift in the corporate ethos.

Innovations driving sustainability

One of the most impactful changes in the welding industry is the adoption of advanced technologies that enhance efficiency and reduce waste. Additionally, the welding industry has optimised the use of material and energy, significantly reducing the carbon footprint associated with manual welding methods.

Sustainable welding processes and products and technologies:

A. Life Cycle Assessment of Welding Processes:

As per one of the research studies on environmental life cycle (LCA) and social life cycle assessment of (SLCA) of various welding processes i.e. Manual Metal Arc Welding ( MMAW), Manual Gas Metal Arc Welding (Manual- GMAW) , Automatic Gas Metal Arc Welding
(Automatic- GMAW) and Automatic Laser Arc Hybrid Welding ( LAHW) , MMAW contributes the highest environmental impact and LAHW contributes the least impact. Automatic GMAW contributes lower environmental impact than Manual GMAW. The main reason is the difference in the consumption of electricity for the welding machine and the filler material.

B. Energy efficiency power sources:

Advanced Power Sources: Inverter-based welding power sources offers greater energy efficiency compared to traditional welding power sources i.e, transductor or magnetic amplifier-based power sources, step switch-controlled machines or thyristor technology. These power sources offer improved power factor resulting in energy saving up to 30%, excellent welding characteristics, less requirement on welder skills, and are lightweight (approximately 60 % reduction in weight as compared to conventional power sources) and compact in size. These features reduce their carbon footprint at the manufacturing stage and during their usage in welding operations .

C. Battery operated power sources:

Recent breakthrough development of battery-operated welding machines in India offers versatile solutions for welding in an environment where access to power is limited. These power sources use lithium-ion batteries, which are Environment friendly due to their ability to store clean energy from a renewable source. These power sources offer exceptional portability with extended battery life and dual input supply options, and reduced carbon emissions. Technology offers a mobile application facility, which provides user with the ability to observe and manage various parameters from a distance i.e. output current, arc force, hot start, battery voltage etc. These are versatile in use as they can be used with either a three phase supply, (if available) or on a battery supply. These battery-operated welding machines are very useful for applications such as outdoor welding, construction sites, pipeline construction, marine applications, railway track repairing etc. Battery-powered welding machines represent a significant advancement in welding technology, offering flexibility, convenience, and efficiency to diverse welding applications.

D. Eco-friendly welding consumables:

Development of copper-free wire at the global level and recent development in India offers an eco-friendly solution for manufacturing of this wire (eliminates hazardous acid and copper salt consumption during wire drawing at the manufacturing stage ). During welding, this wire ( ER 70 S6) emits fewer harmful fumes and reduces welder health concerns While in use, these wires offer excellent wire feeding, stable arc with reduced f luctuations of current, and comparable shelf life. With this, the welding operations can be carried out with higher efficiency to provide a good quality weld and better performance over conventional copper coating wire. These wires offer benefit to user i.e. minimal spatter, low welding fumes, no issue of copper flaking from the surface and the possibility of nozzle choking, longer contact tip life, higher welding speeds etc. In addition, many companies are beginning to offer welding wires spools from biodegradable materials, reducing plastic waste in landfills. Currently, both these above initiatives are at a nascent state at the user end, however, efforts are being made by both the manufacturer of these products and the user industry to establish these eco-friendly initiatives.

E. Electronic gas monitoring & saving system:

Implementing an electronic welding regulator – a device which controls the f low of shielding gas for arc welding process – is recommended. The combination of supply ,distribution of gas flow based on welding current, surge suppression, and quick responding valve shut off enables large-scale reduction in gas usage. These technologies are IoT compatible with 60% gas savings.

F. Advanced Welding Technologies:

One of the most impactful changes in the welding industry is the adoption of technology that enhances efficiency and reduces waste. Laser welding and friction stir welding offer greater precision and lower thermal output, which minimizes  energy consumption and material waste. Even though these technologies may not be able to replace conventional welding processes completely, these processes are being used successfully in high demand sectors i.e, Aerospace & aviation, automotive Industry, space ,railways, shipbuilding, and defence sector.

G. Waste Management :

Leveraging digital welding solutions and precision techniques can greatly reduce material waste. Digital planning tools can help in pre-determining the exact requirement for a project, resulting reduction in over-ordering and waste of resources. Adopting the high precision approach helps industry towards more sustainable practices, ensuring materials are utilised efficiently. Waste management is crucial to reducing the environmental impact of welding. Properly disposing of welding waste products like spent welding electrodes, empty cylinders and other by products is important. Properly labelling and storing waste can also reduce the risk of spills and accidents, and adversely affect the environment. Some materials can be recycled or reused. Metals can be recycled, gas cylinders can be refilled and reused. Materials that cannot be recycled should be labelled and properly disposed of to prevent environmental contamination.

H. Digitization in Welding Industry:

With continuous advancement in technology in welding power sources, it is possible to implement Industry 4.0 in the welding sector. Powerful analytical Software's are available to improve the networking of products and people, which improves efficiency and quality while reducing cost and resources. These software enable comprehensive analysis and custom report generation. It enables comprehensive analysis and custom report generation. 

It has benefits, such as;

• Quality improvement:

Documentation of welding parameters and welder of every run provides long-term traceable welding quality.

• Increase productivity:

Longer arc time per layer improves efficiency. Paperless transfer of all data and WPS (Welding Procedure Specification ) to the workplace reduces non-productive time.

• Pre-set welding parameters reduce the number of error corrections.

• Prompt, consumption-oriented maintenance notice result in fewer downtimes.

I. Enhanced training and certification.

Educating welders about sustainable practice is vital for widespread adoption. Globally, more training programs now incorporate modules on sustainability, teaching new welders about energy efficient technologies and how to minimise resource use. Waste certification program have been updated to include criteria for sustainable practices, pushing entire industry towards greener methods . In India , as well, Welding equipment & consumables manufacturers are contributing by offering courses on sustainable welding practices.

Significance of ISO standards & frameworks in ESG initiatives and reporting:

Over the years, various organisations from the fabrication and welding industries have implemented ISO standards i.e ISO 140001,ISO 45001 ,ISO 3834 and IW 48 : 2024 (en) etc.ISO 14001 - Environmental Management System ( EMS): Helps to identify and control environmental risk associated with industrial activities. Reduce carbon footprint, pollution, and resource depletion through efficient waste and energy management. Demonstrates commitment to sustainability, improving stake holder trust and ESG ratings.

ISO 45001 - Occupational Health & Safety Management system (OH & M): Ensures safety, reducing accidents and health risks, which contributes to the social pillar of ESG. Promotes safe and sustainable work environment risks from workplace incidents. Improves regulatory compliance and corporate reputation in ESG performance. ISO 3834 -Welding Quality Management System: Ensure high-quality welding practices, minimising defects and rework. Reduce material wastage and energy consumption, contributing to sustainable resource usage. Supports compliance with environmental regulations by maintaining process efficiency and reducing emissions.

IWA 48: 2024 ( en): This document provides high level framework and set of principle to give guidance on how to implement and embed environmental,social and governance ( ESG) within the culture of organisation to support management of ESG performance, measurement and reporting enabling consistency, comparability and reliability of ESG reporting and practices globally.

Additional ESG benefits by implementing standards:

Risk mitigation: Reduce legal, environmental and operational risk.

Cost savings: Efficient process, lower waste and energy cost.

Competitive Advantage: ISO certified companies attract investments and customers valuing ESG compliance.

Regulatory Compliance: Aligns with government sustainability polices and reporting framework.

Challenges and future outlook :

During recent years the welding industry has taken commendable steps towards  sustainability driven by technological innovations, adoption of green material, energy efficiency and corporate social responsibility. Despite these advancements, the welding industry still faces challenges in its journey towards sustainability. The high cost of new technologies and need for ongoing training can be barriers especially for smaller operators. Moreover, there is ongoing need for industry wide efforts that unify efforts and create more competitive market for sustainable welding solutions. Looking ahead, the industry is likely to continue its path towards sustainability with even greater integration of cutting edge technologies and materials. Collaboration among companies, governments and educations institutes will be crucial in overcoming current challenges and enhance the industries overall impact on environment. It is time for all stake holders in welding industry to commit to sustainability and work together to undertake transformative changes.