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ZF opens first zero-emission factory in Klášterec, Czech Republic

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  • Plant producing e-mobility products uses 3,400 solar modules to generate electricity  
  • No fossil fuels: Heat pumps reduce heating costs by 50 per cent 
  • A model plant for global ZF production network 

After a renovation period of less than 18 months, ZF’s power electronics production site in KlášterecnadOhří in the Czech Republic is re-opening as its first zero-emission manufacturing facility. The plant is part of the Electrified Powertrain Technology division, supporting the company’s efforts to achieve climate neutrality across all value chains by 2040. It will be used as the blueprint for all ZF plants worldwide. The technology company is gradually shifting to sustainably generated energy at all locations, increasing the energy efficiency of processes, electrifying a significant proportion of its products and utilising recycled materials. 

One of the primary challenges is to convert existing ZF plants around the world so that they can be operated with climate-neutral energy from now on. “The sustainable transformation at the Kláštereclocation is ground-breaking for our entire production network and helps us to significantly reduce greenhouse gas emissions,” says Stephan von Schuckmann, member of the ZF Board of Management. To build strong, sustainable foundations it’s important to equip plants with the ability to generate electricity. In Klášterec, this was accomplished by installing 3,400 solar modules on the campus, meeting roughly 20 per cent of the plant’s annual electricity requirements.  

Any electricity that isn’t generated internally is purchased from renewable sources – mainly wind and hydroelectric power. “Klášterec is our benchmark,” emphasizes Dhanashree Kad, Head of Sustainability at ZF’s Electrified Powertrain Technology Division. As early as 2025, five years ahead of plan, all ZF locations will be fully powered by green electricity, which will be generated in-house or obtained through contracts with renewable energy providers. Additionally, the Czech e-mobility plant’s fossil fuel-dependent gas heating system has been replaced by heat pumps, reducing the plant’s overall annual heating costs by 50 per cent. During colder months, the plant uses the naturally cold external air (free cooling) to cool down the technology within the facility. Various measures for improved thermal insulation and heat recovery round off this local climate concept.  

ZF has operated a plant in Klášterec – which is roughly 100kilometers northwest of Prague – since 1992. Today, the newly remodelled plant has nearly 700 employees and produces power electronic components for electric motors produced by ZF plants in Germany and Serbia. Customers include international car manufacturers.