From its launch, ECOFACT designed and implemented a holistic monitoring architecture that links local data acquisition systems with a central platform. Smart sensors and interoperability modules were deployed in all demonstrators, enabling the seamless flow of energy and production data. This information was channelled to the Energy and Resource Management System (ERMS), which supports predictive maintenance, production planning, resource optimisation and energy flexibility.
A major innovation was the creation of digital twins for critical processes such as beer fermentation, washing machine assembly, biscuit ovens and automotive paint booths. These virtual models allow operators to simulate scenarios, forecast energy use, detect inefficiencies and anticipate failures. In parallel, dynamic LCA/LCCA models were connected to production data, enabling real-time evaluation of environmental and cost impacts.
The platform was validated under real industrial conditions, reaching TRL7. Results include energy savings of up to 25% in specific processes, significant reductions in downtime and material losses, and measurable decreases in CO2 emissions (5–10%). In addition, optimised planning and predictive maintenance reduced operational costs, including an estimated €250,000 in maintenance savings across the pilots.
ECOFACT also worked beyond the demonstrators. Replication guides were created, and five feasibility studies with external companies in food, packaging, wine and dairy confirmed the wider applicability of the methodology. Dissemination was extensive, with nine newsletters, six webinars, 25+ international conferences, and training sessions at pilot plants. In total, the project reached over 50 institutions and more than 8,000 citizens through communication campaigns.
Exploitation planning was consolidated in the Final Exploitation Plan, defining business models such as Software-as-a-Service, licences and partnerships. Key Exploitable Results (KERs) include the ECOFACT platform, digital twin modules, predictive algorithms and dynamic LCA tools. Protection strategies were prepared through an IPR framework to secure sustainability and market readiness.
Finally, ECOFACT contributed to standardisation with the publication of CWA 18188, providing guidelines for sustainable manufacturing certification. This ensures that the project’s legacy will influence both industrial practices and European policy frameworks.
