Mazak: The Machine Tools Powering Sustainable Manufacturing

Mazak Europe is part of the Yamazaki Mazak Corporation, one of the world’s leading manufacturers of CNC machine tools and laser cutting machines. Mazak's high-performance CNC machines shape the components that power modern industry. But as the world grapples with climate change, this manufacturer is proving that sustainability and precision can go hand in hand.

At Mazak's European headquarters in Worcester, Engineering Manager Chris Johnson is leading a transformation that goes far beyond the factory floor. The company's Go Green strategy aims to slash carbon emissions by 50% by 2030, and they're well on their way to achieving it.

Mazak's machines create everything from artificial hip joints to the tooling that shapes Formula One steering wheels. These critical components serve industries where precision is paramount, yet traditional manufacturing has been notoriously energy intensive.

Rather than accepting high energy consumption as inevitable, Mazak is reimagining every aspect of how their machines operate. The challenge is significant: Precision manufacturing requires exact tolerances and consistent performance, leaving little room for compromise.

Mazak's strategy is ambitious. "Our target is to have a 50% reduction in our carbon footprint by the year 2030," says Johnson. This isn't just about their own operations—it encompasses direct emissions, purchased electricity, and the wider impact across their supply chain and customer base.

Rather than seeking dramatic overhauls, Mazak focuses on continuous improvement across countless small details. As Johnson puts it: "It's a Japanese approach…where lots of small changes add up to being a very big impact."

This methodology is delivering remarkable results. The company's new NEO range represents a breakthrough in sustainable manufacturing with the i-800 NEO achieving "22% reduction in CO2 emissions compared to the same machine that we were making previously."

The secret lies in optimising every component around the cutting process. Whilst the fundamental physics of metal cutting remains unchanged, Mazak has transformed the ancillary systems that support it.

Johnson is frank about the constraints: "There's only so much we can do because we can't break the laws of physics." The energy required to cut metal is fixed, but everything else can be improved.

The focus has been on the supporting systems that consume significant power. Pumping systems, which circulate coolants and other fluids around the machines, presented a major opportunity. By redesigning these systems to reduce pumping losses, Mazak has achieved substantial energy savings without compromising performance.

One of Mazak's most innovative features is the energy dashboard integrated into their new machines. This real-time monitoring system gives operators unprecedented visibility into power consumption.

"On our control systems, we've integrated almost like a smart meter that you'd have in your house," Johnson explains. The dashboard shows current energy use and cumulative consumption, enabling operators to make informed decisions about efficiency.

This transparency is transforming manufacturing practices. Where operators once relied on intuition, they now have "verifiable numbers" to guide their optimisation efforts. The result is more efficient production and reduced environmental impact.

Sustainability at Mazak isn't just about energy efficiency, it's about longevity. The company takes pride in supporting machines that have been running for decades, with some units remaining productive after 40 or 50 years of operation.

This commitment to durability has significant environmental benefits. As Johnson points out, "The carbon emissions in making a brand-new machine is roughly the same as a small family hatchback car." By extending machine life through comprehensive support, Mazak helps customers avoid the emissions associated with frequent replacements.

The approach reflects a circular economy mindset where the goal is maximum utility from every manufactured product. When machines are built to last and properly maintained, the environmental cost per component produced drops dramatically.