Improving environmental and economic sustainability of cutlery manufacturing in adeveloping nation through energy reduction and energy transition initiatives.

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Manufacturing industries are vital for economic development, but they cause significant environmental damages. As there are scarce research studies for this industrial sector from developing countries, this article reports a comprehensive environmental and economic analyses for cutlery manufacturing in Pakistan. SimaPro 9.5 was used as a modelling software tool, while ReCiPe 2016 methods were used to evaluate various midpoint and endpoint environmental impacts. Various economic indicators were used to evaluate the economic performance of different alternative scenarios. The results revealed that injection molding process, due to its energy-intensive nature caused the most environmental impacts as compared to other manufacturing processes. Global warming and terrestrial ecotoxicity were the most affected impact categories with values of 11.8 kg CO2 eq and 12.0 kg 1,4-DCB, respectively. Meanwhile, at endpoint level, human health category was most damaged as compared to others. Based on technical process intervention and energy transition, four different alternative scenarios were developed. In comparison with baseline scenario, the alternative scenario with double-cavity mold resulted in a reduction of more than 30% for various impact categories. The other three alternatives were grounded on the use of solar energy (50% or 100%) and injection mold with double or single cavity. Overall, the alternative scenario with 50% solar energy and double-cavity mold was the best solution that showed more than 50% reduction in most of the impact categories, less than 3-year payback time, 2.12 million (Pakistani Rupees) net present value, and 36.3% of return on investment. This study clearly shows the importance of renewable energy resources and simple changes in process technology for improving sustainability performance. The relevant stakeholders can effectively use the results and methodology of this study as a reference and guide for future research and practical interventions, especially in developing countries.