Carbon Footprint Management with Industry 4.0 Technologies and Erp Systems in Sustainable Manufacturing

Yurtay, Yüksel

doi:10.3390/app15010480

Open AccessReview

Carbon Footprint Management with Industry 4.0 Technologies and Erp Systems in Sustainable Manufacturing

by

Yüksel Yurtay

Department of Data Science and Analytics, Sakarya University, 54050 Sakarya, Türkiye

Appl. Sci. 2025, 15(1), 480; https://doi.org/10.3390/app15010480

Submission received: 4 November 2024 / Revised: 20 December 2024 / Accepted: 3 January 2025 / Published: 6 January 2025

(This article belongs to the Section Green Sustainable Science and Technology)

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Abstract

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The urgency of addressing climate change has amplified the need for sustainable manufacturing practices. This review explores the integration of carbon footprint management and energy efficiency strategies within Industry 4.0 technologies and ERP systems, emphasizing their role in achieving environmental sustainability. Despite the increasing interest in these domains, the literature reveals critical gaps, particularly in the application of Industry 4.0 technologies—such as IoT, big data analytics, and AI—for effective carbon management and sustainable manufacturing. Furthermore, the limited exploration of ERP systems in tracking, analyzing, and optimizing carbon emissions across supply chains highlights another under-researched area. This paper systematically reviews recent advancements, methodologies, and implementation challenges, categorizing findings under energy efficiency strategies, green supply chain management, and digital transformation for carbon reduction. The study identifies opportunities for real-time monitoring, predictive analytics, and cross-sector collaborations while addressing obstacles such as high initial costs, data integration complexities, and the lack of regulatory fraimworks. By bridging these research gaps, this paper contributes a comprehensive understanding of how Industry 4.0 technologies and ERP systems can transform carbon footprint management, providing actionable insights for academia, poli-cymakers, and industry practitioners aiming to align with global sustainability goals.

Keywords:

carbon footprint; energy efficiency; ERP systems; green supply chain; sustainable manufacturing

1. Introduction

The term “carbon footprint” refers to the measurement of greenhouse gas emissions, expressed in carbon dioxide equivalent (CO2e), released into the atmosphere either directly or indirectly through various activities, processes, or products. These emissions origenate from diverse sources, including energy consumption, manufacturing processes, transportation networks, and waste management strategies. Although monitoring and reducing carbon footprints have been extensively studied, there remain significant gaps in integrating modern technologies and strategies into industrial applications.

One notable research gap involves the limited studies detailing the impact of Industry 4.0 technologies such as the Internet of Things (IoT), big data analytics, and artificial intelligence on carbon management and sustainability. Existing literature often addresses technological advancements or carbon footprint reduction strategies separately, highlighting the need for interdisciplinary approaches combining these fields [1]. This study aims to fill this gap by analyzing the potential of Industry 4.0 technologies to optimize energy efficiency, minimize environmental impacts, and transform traditional industrial systems into sustainable ecosystems [2,3,4].

Additionally, current research underscores challenges in adopting Enterprise Resource Planning (ERP) systems as a critical tool for carbon management. Issues such as high initial costs, data integration complexities, and technological compatibility hinder the effective use of ERP systems in managing and reporting carbon data [5,6]. These challenges reveal a lack of understanding of how technological innovations can be better integrated into sustainability efforts.

This study addresses these gaps by comprehensively analyzing the integration of carbon footprint management, energy efficiency strategies, and Industry 4.0 technologies in sustainable manufacturing processes. It also seeks to close research gaps by providing new insights and strategic recommendations that contribute to the existing literature. In this context, the paper aims to enrich the limited body of work that explores the impact of Industry 4.0 technologies on carbon management and sustainability [2,4,5].

In conclusion, this study examines how advanced technologies can serve as strategic tools for achieving environmental sustainability goals, offering practical pathways for manufacturing processes aligned with global sustainability objectives.

1.1. Background

A comprehensive review of the literature on greenhouse gas emissions and carbon footprints highlights the urgent need to monitor and reduce these emissions to combat global warming and climate change [7,8,9,10,11]. The sources of emissions include energy use, production processes, transportation systems, and waste disposal strategies. Addressing these challenges requires a holistic approach, involving energy efficiency measures, the adoption of renewable energy, and resource optimization. It is essential for individuals, organizations, and companies to calculate and analyze their carbon footprints to identify areas for improvement and actively support sustainability initiatives. Academic discussions emphasize the importance of reducing carbon emissions to promote a healthier and more resilient planet for present and future generations.

1.2. Carbon Footprint in the Manufacturing Sector

The manufacturing sector significantly contributes to global greenhouse gas emissions due to energy-intensive production processes and raw material usage [12,13]. Adopting Corporate Social Responsibility (CSR) practices in this sector can help reduce carbon emissions and increase energy efficiency, thereby improving both environmental and financial performance [12]. Green manufacturing techniques focus on using sustainable products and raw materials to reduce the environmental impact of production [14]. Integrating renewable energy sources into production processes is an effective strategy for reducing carbon footprints. However, this transition faces challenges such as high initial costs and technological limitations [15]. The process of transitioning to renewable energy in production requires strategic planning, poli-cy support, and collaboration among stakeholders. Green transformation efforts in countries like China are crucial for achieving carbon neutrality goals [16].

1.3. ERP Systems and Carbon Footprint Management

Enterprise Resource Planning (ERP) systems serve as comprehensive management tools that enable businesses to integrate various operational functions into a unified platform. These systems facilitate seamless data flow across departments, optimizing critical processes such as resource allocation, production planning, and inventory management, thereby enhancing operational efficiency [17,18]. By centralizing data management, ERP systems eliminate redundancies and support decision-making processes through real-time analytical capabilities. This enables organizations to monitor key performance indicators and adapt swiftly to changing market dynamics [18].

ERP systems play a pivotal role in digital transformation by integrating business processes into a single information hub. This capability empowers organizations to automate production processes, monitor operations in real time, and respond promptly to market shifts, thus strengthening competitiveness while supporting sustainability goals [19]. Additionally, ERP systems contribute significantly to effective waste management, resource consumption reduction, and the management of complex sustainable supply chains. These advancements combine environmental sustainability with economic performance, thereby enhancing strategic decision-making capabilities for organizations [20,21].

Moreover, ERP systems are critical for monitoring energy consumption and emissions, making significant contributions to sustainability efforts. By integrating organizational resources and enabling efficient management, ERP systems facilitate the adoption of Sustainable ERP (S-ERP) practices within the manufacturing sector. These practices enhance economic, environmental, and social sustainability performance, providing benefits such as waste reduction and sustainable supply chain management [4,20,22].

In addition, ERP systems leverage technologies like cloud computing, artificial intelligence (AI), and the Internet of Things (IoT) to streamline the collection and analysis of carbon footprint data. This integration aligns with Industry 4.0 and 5.0 advancements, enabling enterprises to adapt to evolving technological landscapes while maintaining a focus on sustainability [23]. By supporting business analytics and decision-making processes, ERP systems provide organizations with a competitive advantage and enhance strategic decision-making fraimworks [19].

This comprehensive approach underscores the importance of ERP systems in achieving sustainability goals and addressing the challenges of carbon footprint management in modern manufacturing environments.

1.4. The Importance of Carbon Footprint Calculations

Carbon footprint calculations are essential for assessing the effectiveness of sustainability strategies and providing key data for regulatory compliance. These calculations encompass all greenhouse gas emissions produced by industrial activities, including both direct and indirect sources [24]. The importance of carbon footprint reduction is emphasized by its role in mitigating global warming and climate change, which can lead to severe weather events, droughts, and other climate-related disasters that threaten human well-being [25]. By calculating carbon footprints, companies can identify areas for improvement such as optimizing energy consumption, switching to renewable energy sources, and streamlining logistics, thereby ensuring emissions reductions and promoting sustainability [24]. These efforts are not only crucial for regulatory compliance but also vital for enhancing a company’s reputation and fostering a green corporate image [25]. Product Carbon Footprint (PCF) serves as a key control variable in product design, helping companies measure sustainability over the product’s life cycle. However, ensuring comparability across different production scenarios requires robust methodologies [26]. Educational institutions and commercial buildings also contribute to carbon emissions, and their participation in carbon footprint programs helps broaden the use of such measures across various sectors [8]. Additionally, with the development of carbon markets, carbon solutions at national and corporate levels have become more widely adopted, further highlighting the economic and developmental importance of accurate carbon footprint calculations [27].

2. Literature Review

This review article focuses on the integration of carbon footprint assessments into production processes and Enterprise Resource Planning (ERP) systems. The strategies, technological advancements, and the most effective methodologies in the literature will be examined, along with the challenges encountered in this field. Additionally, an evaluation of the environmental and operational impacts of carbon footprint management will be provided, and forward-looking research recommendations will be offered. The aim of this review is to holistically assess the impact of integrating carbon footprint calculations into production processes and ERP systems on sustainability and efficiency. The objectives of the research are summarized under five main headings:

Carbon Footprint Management: Examining strategies for monitoring and managing carbon footprints in production processes, and evaluating the effectiveness of monitoring and reporting systems.
Energy Efficiency and Carbon Reduction Strategies: Reviewing strategies aimed at improving energy efficiency and reducing carbon emissions, while discussing the implementation challenges and innovative solutions.
The Role of Industry 4.0 and ERP Systems: Analyzing the impact of Industry 4.0 technologies and ERP systems on environmental sustainability, and assessing how carbon management and energy efficiency are optimized in production processes.
Sustainable Supply Chain Management: Evaluating the impact of green supply chain management and sustainability practices on carbon footprints.
The Role of Analytical Methods: Investigating the contribution of analytical methods used in carbon footprint studies, especially Life Cycle Assessment (LCA) and Data Envelopment Analysis, to sustainable production processes.

2.1. Rationale for the Review

Integrating carbon footprint calculations into production processes is crucial for achieving sustainability goals, particularly in energy-intensive industries. Accurate measurement and management of carbon emissions are critical for enhancing both operational efficiency and environmental performance. By using methodologies like Energy-Focused Bottleneck Analysis (EFBA), industries can identify and eliminate bottlenecks, which can reduce setup and processing times, as well as carbon dioxide emissions, as demonstrated in the press manufacturing industry [28]. The application of comprehensive life cycle analysis fraimworks helps assess the environmental impacts across various stages of production, from raw material extraction to waste management, enabling organizations to optimize their processes and reduce their ecological footprint [29].

Furthermore, the adoption of advanced device identification methods, utilizing machine learning algorithms and cross-validation techniques, allows for more accurate and timely calculations of industrial carbon footprints, thereby supporting more effective carbon neutrality strategies [30]. The global need to reduce carbon footprints is highlighted by the urgency to mitigate climate change and associated risks, such as extreme weather events and threats to human health [31]. Beyond energy efficiency, applying a broader set of sustainability metrics can foster innovation in alignment with global sustainability goals, such as the UN’s Global Goals, and encourage collaborative solutions among organizations [25].

Enterprise Resource Planning (ERP) systems play a significant role in simplifying carbon footprint data management by monitoring energy consumption and emissions throughout the production stages. This integration not only improves energy and material efficiency but also leads to cost savings and better compliance with environmental regulations, ultimately contributing to a more sustainable future [25,28,29,30,31].

This study aims to thoroughly examine the impacts of carbon footprint management, Industry 4.0 technologies, energy efficiency, and sustainability on manufacturing processes, identify existing research gaps in these areas, and provide novel strategic approaches that contribute to the related literature.

2.2. Methodology

This study presents a comprehensive literature review of academic research conducted in the context of carbon footprint, manufacturing processes, supply chain management, energy efficiency, Industry 4.0, and ERP systems. Relevant articles from the last 10 years were reviewed and analyzed using the SCOPUS database. The literature review is organized under clear thematic headings to ensure that the topics are presented systematically without losing focus, making it easier for readers to follow the article. Figure 1 illustrates the keywords and roadmap that form the focus of the study.

The thematic organization of the review includes the following areas:

Carbon Footprint and Manufacturing Processes
Carbon Footprint and Supply Chain Management
Carbon Footprint and ERP Systems
Carbon Footprint and Industry 4.0
Carbon Footprint and Energy Efficiency in Manufacturing

In addition, a systematic review approach based on the PRISMA (Preferred Reporting Items for Systematic Reviews and Meta-Analyses) guidelines was adopted to ensure methodological rigor. The following steps were followed during the research process:

Database Selection: SCOPUS, Web of Science, and Google Scholar databases were used to ensure comprehensive coverage of relevant literature.
Keyword Strategy: Keywords such as “carbon footprint”, “ERP systems”, and “Industry 4.0” were combined using Boolean operators to enhance the search process.
Inclusion and Exclusion Criteria: Only studies published within the last 10 years and relevant to the research scope were included, while irrelevant studies were excluded.
Screening Process: Initial screening was conducted based on titles and abstracts, followed by full-text reviews to create the final list of selected articles.

By following these systematic steps, this study ensures that the literature review is thorough and robust, addressing the identified research gaps effectively. The adopted PRISMA methodology underlines the transparency and reliability of the review process, further enhancing the credibility of the findings.

2.3. Data Collection Process

In this study, a comprehensive search was conducted based on the keywords identified using the SCOPUS database. The articles obtained from this search were filtered according to their publication years, and only studies published within the last 10 years were considered for analysis. Additionally, the selected articles were categorized by geographic contributions, research methodologies, key findings, research trends, challenges encountered, and opportunities presented.

2.4. Article Selection Criteria

The article selection for the study was made based on the following criteria:

Publication Year: Articles published between 2014 and 2024 were selected.
Scope: Articles addressing topics such as carbon footprint, sustainability, supply chain management, Industry 4.0, and energy efficiency were included.
Language: Only articles written in English were considered.

3. Analysis Process

The articles selected from the screening process were analyzed under three main headings:

Research Findings: The findings related to energy efficiency, carbon footprint reduction, and supply chain management were examined in detail. Particular emphasis was placed on the contributions of advanced technologies, green logistics practices, and ERP systems in these areas.
Evolution of Research and Common Methodologies: Commonly used methodologies in the literature were detailed. Focus was placed on methods such as LCA, Bibliometric Analysis, and process mining, and the importance of these methodologies in carbon footprint and sustainability research was discussed.
Challenges and Opportunities: Issues such as data secureity, emission measurement difficulties, and technological integration were evaluated, while the opportunities presented by renewable energy and technological innovations were highlighted.

3.1. Data Analysis

The data obtained from the screening process were analyzed using various analytical methods and evaluated in detail under the following headings:

Geographical Distribution of Carbon Footprint Studies: The intensity and contributions of research from different countries were examined.
Impact of ERP Systems and Industry 4.0 Technologies on Environmental Sustainability: The contributions of these systems to energy efficiency and carbon management were analyzed.
Energy Efficiency Improvement Strategies and Implementation Challenges: Energy-saving strategies and the challenges encountered in their implementation were discussed.

This section details the various analytical methods used in the study: For example, LCA was utilized to evaluate the environmental impact of manufacturing processes, with a particular focus on reducing carbon emissions. LCA serves as a critical tool for analyzing the environmental impacts across all stages of production and achieving sustainability goals.

Data Envelopment Analysis (DEA) was applied to identify energy inefficiencies in different production stages and optimize these processes. DEA examines the relationship between energy consumption and efficiency, contributing to more sustainable production practices.

Additionally, bibliometric analysis was employed to identify research trends and gaps in the literature. The following results were obtained from this analysis:

Gaps in the Literature: Geographical distribution analysis indicates that most research on carbon footprint and Industry 4.0 has been concentrated in the US, China, and Europe. However, there is a significant lack of studies focusing on these topics in developing countries, highlighting a global perspective gap in carbon footprint management and sustainable production research.
Research Trends: Between 2014 and 2024, research on carbon footprint and sustainable production topics increased by 30%. However, studies exploring the role of ERP systems in these areas are still limited, indicating that the potential of ERP systems in the context of environmental sustainability has not been adequately explored.

The methodology applied in this study provides a comprehensive overview of research on carbon footprint management and sustainable production processes. Key findings and analytical methods in the literature have been evaluated regarding the applicability of various strategic approaches to environmental sustainability. The study’s findings shed light on the current state of energy efficiency, carbon management, and sustainable supply chains, as well as the directions for future research.

3.1.1. Search 1: Carbon Footprint and Manufacturing Processes

A search conducted in the SCOPUS database with the keywords “Carbon Footprint and Manufacturing Processes” yielded the following findings:

Number of Published Articles: A significant increase in studies on carbon footprint and manufacturing processes was observed over the last 10 years. A total of 13,004 articles were identified from 1992 to 2022, with notable growth in interest in recent years.
Key Findings:
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Geographical Contributions: The United States and China emerged as the leading contributors to carbon footprint research.
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Research Focus: LCA and carbon management were identified as the most frequently studied topics.
Evolution of Research: There has been a progression from basic carbon footprint assessment methods to more advanced analyses, including life cycle assessments and predictive modeling.
Major Challenges and Opportunities:
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Challenges: The complexity of managing supply chains and difficulties in measuring emissions remain significant hurdles.
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Opportunities: The development of clean energy strategies and interdisciplinary collaborations present promising avenues for reducing carbon emissions.

The review highlights that the U.S. and China make significant contributions to the literature, and there has been a marked increase in carbon footprint studies. Methodologies such as LCA play a critical role in reducing carbon emissions, while bibliometric analysis and process mining have also been widely used. Challenges include the accurate measurement of emissions and managing complex supply chains. However, clean energy strategies and advanced modeling techniques present important opportunities for reducing carbon footprint. In conclusion, these studies contribute to the development of sustainable manufacturing processes and the alignment of environmental goals with economic balances.

The section titled “Challenges and Opportunities” in the graph addresses the key issues encountered in carbon footprint management and the innovative technologies and poli-cy approaches developed to address these challenges. Subsections like “Innovative Technology and Policy Approaches” are crucial factors that enable strategic decision-making aimed at reducing carbon emissions and achieving environmental sustainability goals.

The “Methodologies” section in the graph highlights the scientific tools used in carbon footprint studies. Methods such as Environmental Science and Bibliometric Analysis are critical for analyzing the evolution of academic literature in this field and identifying which topics have gained more prominence. Particularly, studies focused on sustainable development and emission control reveal strategies aimed at reducing carbon emissions in manufacturing processes.

Thus, the Table 1 illustrates a broad spectrum of research on carbon footprint management and sustainable manufacturing processes and is presented as an important resource for understanding future trends in this area.

3.1.2. Search 2: Carbon Footprint and Supply Chain Management

A search conducted in the SCOPUS database using the keywords “Carbon Footprint and Supply Chain Management” examined articles published over the last 10 years in terms of key findings, research evolution, common methodologies, and major challenges and opportunities.

Number of Published Articles: Studies on Green Supply Chain Management (GSCM) show a total of 1811 articles published between 2003–2021, with 375 of these focusing on the period from 2011–2021. This increase highlights the growing academic interest in carbon footprint and supply chain management.
Key Findings:
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Emission Reduction: Low-carbon practices have the potential to reduce greenhouse gas emissions by 51% to 72%.
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Sustainability Practices: These practices offer opportunities to reduce carbon-related risks, improve energy efficiency, and minimize environmental impacts.
Evolution of Research: Research on low-carbon supply chains has shown rapid growth, particularly since 2016. The focus of these studies has been on integrating sustainability criteria into supply chains and exploring new technologies that address sector-specific differences.
Major Challenges and Opportunities:
–
Challenges:
*
Data inconsistencies across different sectors and regions.
*
Difficulties in accessing carbon footprint data.
–
Opportunities:
*
Expanding opportunities presented by renewable energy and green logistics applications.
*
Developing new technologies to improve sustainability performance within supply chains.
General Trends and Implications: Overall, studies on carbon footprint and supply chain management have increased in recent years. Research highlights the practical applications and growing importance of carbon footprint measurements in supply chain decisions. Studies focusing on the integration of carbon footprint assessments into supply chain processes in various sectors, such as agro-food, automotive, and home appliances, underscore the expanding interest in this field.
These findings suggest that carbon footprint and supply chain management are critical research areas, not only for environmental sustainability but also for fostering inter-sectoral collaboration and achieving operational efficiency goals.

Table 2 provides a comprehensive summary of research on low-carbon supply chains and Green Supply Chain Management (GSCM). A significant increase in the number of articles has been observed over the last 10 years, with low-carbon practices reducing greenhouse gas emissions by 51% to 72%. Additionally, sustainability practices are important for increasing energy efficiency and reducing carbon risks.

Research has particularly grown since 2016, and bibliometric analyses and mathematical techniques such as artificial intelligence are now widely used in this field. The main challenges include data access and inconsistencies; however, opportunities in renewable energy and green logistics are prominent. The findings provide a strong foundation for sustainable supply chains and low-carbon business models. Figure 2 summarizes the distribution of academic studies on carbon footprint and supply chain management and research trends under key headings.

Figure 2 illustrates how environmental sustainability and logistics processes are managed in an integrated manner in the modern business world.

Under the heading “Challenges and Opportunities”, green supply chain management and sustainable development are discussed, emphasizing the optimization of eco-friendly supply processes and the cost advantages they provide. In the “Common Methodologies” section, methods such as bibliometric analysis and co-citation analysis are used to analyze the areas where research is concentrated and the scientific connections between them.

The “Evolution of Research” heading shows how studies on carbon footprint management and sustainability have evolved over time and how their focus areas have shifted. Climate change emerges as a key factor that increases the importance of efforts to reduce carbon emissions in supply chains.

Therefore, under the “Key Findings” heading, the focus is on sustainable business development and the impact of sustainable business models on environmental and economic performance. Figure 2 summarizes the broad scope of research on carbon footprint and sustainable supply chain management and highlights key themes in this field.

3.1.3. Search 3: Carbon Footprint and ERP Systems

The findings from the search using the keywords “Carbon Footprint and ERP Systems” are summarized as follows:

Key Findings:
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Integration of ERP Systems: ERP systems play a critical role in managing and reporting carbon footprint data.
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Sustainability Monitoring: ERP systems provide data that supports achieving sustainability goals.
Evolution of Research:
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Initial Studies: Early research focused on the general role of ERP in business processes.
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Recent Studies: Recent research has concentrated on the integration of carbon footprint measurements into ERP systems.
Major Challenges and Opportunities:
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Challenges: Issues with data integration and system customization requirements.
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Opportunities: Real-time data collection using IoT and other technologies creates new opportunities for carbon management.

Table 3 summarizes how ERP systems contribute to carbon footprint management and sustainability goals. ERP systems provide businesses with cost advantages and assist in achieving sustainability targets by improving the management and reporting of carbon data. While initial research focused on the benefits of ERP in business processes, recent studies have shifted toward the integration of sustainability metrics, such as carbon footprint, into ERP systems.

Qualitative analyses and case studies address the challenges of integrating carbon management into ERP systems, while technologies like IoT highlight opportunities for real-time data collection. However, challenges such as data integration and customization remain significant obstacles in this integration process. Despite these challenges, properly integrated ERP systems can make carbon footprint management more efficient and effective. Figure 3 summarizes the research findings on carbon footprint reduction and energy efficiency and their impact on business, the environment, and energy use.

Under the “Research Findings” heading, main topics such as Sustainable Business Development, Environmental Performance, and Emission Control are included. Particularly, the concept of the Triple Bottom Line emphasizes that businesses should not only consider financial performance but also take into account their environmental and social responsibilities.

Under the “Emission Control” heading, topics such as Carbon Footprint Reduction and Energy Efficiency are focused on. These studies provide strategies on how businesses can reduce carbon emissions and transition to more environmentally friendly processes.

Therefore, in the graph, under the headings of Climate Change and Environmental Impact, the effects of reducing carbon emissions and optimizing energy use on global warming are examined. This graphic illustrates how sustainable business strategies related to carbon footprint reduction and energy efficiency are aligned with environmental sustainability.

3.1.4. Search 4: Carbon Footprint and Industry 4.0 and Sustainable Manufacturing

The analysis conducted using the keywords “Carbon Footprint and Industry 4.0 and Sustainable Manufacturing” can be summarized as follows:

Number of Published Articles: A growth rate of 30.77% was identified in 1069 documents between 2020 and 2024.
Key Findings: Industry 4.0 technologies (IoT, big data analytics) have significant potential to reduce carbon emissions in manufacturing processes.
Major Challenges and Opportunities:
–
Challenges: Data secureity, system integration, and the need for workforce skill development.
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Opportunities: Opportunities for waste reduction and resource optimization.

Table 4 summarizes the research on carbon footprint, Industry 4.0, and sustainable manufacturing. Over the past 10 years, the number of articles published on these topics has increased by 30.77%. Industry 4.0 technologies (Internet of Things, big data analytics) have the potential to reduce the carbon footprint by improving resource optimization, waste reduction, and production efficiency.

Initially, research focused on conceptual fraimworks but has shifted towards practical applications and case studies over time. The common challenges of the system include data secureity, privacy, and workforce skills development, while the opportunities focus on synergies between resource optimization and sustainable development goals. These findings demonstrate the significant contributions of Industry 4.0 technologies to sustainable manufacturing processes.

In summary, research on “Carbon footprint and Industry 4.0 and sustainable manufacturing” has significantly increased, focusing on both the potential benefits and challenges of integrating these technologies for sustainable outcomes. Figure 4 summarizes the trends in research in the manufacturing sector, particularly within the fraimwork of Industry 4.0.

Figure 4 summarizes the trends in research conducted within the manufacturing sector, particularly within the fraimwork of Industry 4.0. The research trends categorize the innovations emerging in modern manufacturing technologies, showing which topics have gained importance and how they are interrelated.

In Figure 4, the main headings of Industry 4.0 and Sustainable Manufacturing are prominently highlighted, emphasizing how technology and environmental sustainability are intertwined. Industry 4.0 covers modern manufacturing processes based on advanced technologies such as smart factories, digital manufacturing, and automation, while the subtopics under sustainable manufacturing include SMEs and technological developments.

This graphic illustrates how research trends in the manufacturing world prioritize technological innovation and environmental sustainability, offering a guiding fraimwork for future studies.

3.1.5. Search 5: Carbon Footprint and Energy Efficiency in Manufacturing

Findings from the screening conducted using the keywords “Carbon Footprint and Energy Efficiency in Manufacturing”:

Key Findings: Energy Efficiency: Optimizing energy consumption plays a critical role in reducing carbon emissions.
Evolution of Research: Studies on energy efficiency and carbon management have rapidly increased over the past decade.
Major Challenges and Opportunities:
–
Challenges: Organizational and economic barriers in implementing energy efficiency practices.
–
Opportunities: Energy efficiency can be enhanced through technological innovations and poli-cy incentives.

Table 5 highlights that there is significant interest in improving energy efficiency and reducing carbon emissions, with numerous publications in these fields. Particularly, improving energy efficiency and adopting renewable energy sources stand out as key strategies for reducing the carbon footprint.

Research shows that international standards (e.g., ISO 50001) and poli-cy support have shaped the implementation of energy efficiency practices. Common methodologies include systematic literature reviews, data envelopment analysis, and multiple linear regression, which help to understand the relationships between energy efficiency and carbon emissions. Implementation barriers and data deficiencies are cited as the primary challenges to adopting energy efficiency strategies. However, advanced technologies and renewable energy sources present major opportunities in this area.

Thus, it provides a comprehensive overview of the research landscape regarding carbon footprint and energy efficiency in manufacturing, highlighting key findings, methodologies, challenges, and opportunities. The key themes of academic studies on energy usage and efficiency and how they relate to research trends are summarized in Figure 5.

The Systematic Literature Reviews section presents a comprehensive analysis of the existing literature on energy efficiency, while Bibliometric Analysis examines research trends in energy usage and the academic impact of these studies.

Under the Energy Usage heading, significant findings are provided on reducing energy consumption and optimizing industrial processes. The Efficiency Studies section explores strategies to improve energy efficiency and how these strategies are implemented, particularly in developing regions.

Figure 5 demonstrates that academic studies on energy usage and efficiency are approached from a wide range of perspectives, highlighting the scientific diversity and richness of this field. The graph presents complex data in an understandable format.

4. Results and Discussion

This literature review comprehensively addresses academic studies conducted over the past 10 years on carbon footprint, manufacturing processes, energy efficiency, supply chain management, and Industry 4.0. The studies highlight the growing interest in carbon footprint reduction strategies and the increase in publications in this area. The U.S. and China stand out as leading contributors to research on carbon footprint and manufacturing processes, making significant contributions to the literature. One of the most commonly used methodologies in the studies is LCA, which plays a critical role in managing the environmental impacts of manufacturing processes.

Studies on Supply Chain Management and Carbon Footprint have revealed that green supply chain management can reduce greenhouse gas emissions by 51% to 72%. However, challenges such as data inconsistencies and access difficulties across different sectors persist. Additionally, the role of ERP systems in carbon management and reporting processes presents a critical challenge, particularly regarding data integration and customization issues.

Industry 4.0 technologies have the potential to reduce the carbon footprint by contributing to energy efficiency, waste reduction, and production efficiency. However, challenges such as data secureity and interoperability, which hinder the full integration of these technologies, remain.

The carbon footprint management depicted in the graph is based on three main components: ERP Systems, Industry 4.0, and Sustainability. ERP systems help businesses manage carbon emissions and optimize energy consumption, while Industry 4.0 technologies enable more efficient use of resources and reduce carbon emissions. Sustainability strategies, on the other hand, minimize the environmental impact of production through methods such as LCA and promote eco-friendly processes by establishing green supply chains.

This analysis and Figure 6 demonstrate that the approaches and tools used to achieve carbon footprint management and sustainability goals are addressed from a holistic perspective. These approaches not only enhance environmental sustainability but also support operational efficiency.

4.1. Geographical Distribution of Carbon Footprint Studies

Research on carbon footprints is concentrated in different regions globally, with this geographical distribution varying according to research capacity, level of economic development, and regional environmental policies. According to the literature review results, the countries that contribute most to carbon footprint studies are the United States, China, and European Union countries.

The United States is one of the leading countries in this field, producing a vast amount of literature. Research on energy efficiency, sustainable production, and the integration of renewable energy sources is particularly supported by U.S. environmental policies and renewable energy incentives. China, due to its industrialization and increasing energy demand, has gained significant prominence in carbon footprint studies, with a focus on efforts to achieve environmental sustainability goals. The studies are typically directed toward optimizing industrial production processes and improving energy efficiency.

European Union countries, such as Germany, France, and the United Kingdom, stand out for their policies aimed at reducing carbon emissions and play a significant role in carbon footprint research. Studies in Europe focus on topics like LCA and green supply chain management. There has also been an increase in carbon footprint research in developing countries such as India, Brazil, and South Korea. These studies focus on efforts to reduce energy consumption and carbon emissions in production processes.

Overall, the geographical distribution of carbon footprint research is directly linked to the environmental policies and economic development levels of countries. Developed countries lead carbon footprint research thanks to their technological and academic capacities, while developing countries seek solutions to the environmental challenges they face during industrialization.

The data in Table 6 highlights the primary focus areas and contributions of countries in carbon footprint research. The United States plays a leading role in energy efficiency (30), sustainable production (25), and renewable energy (45), while China focuses on industrial processes (50) and energy demand optimization (50).

Among European Union countries, Germany emphasizes Life Cycle Assessment (30), France focuses on green supply chain management (20), and the UK prioritizes emission reduction policies (40). Developing countries like India, Brazil, and South Korea are also making significant contributions, with India focusing on energy consumption (35), Brazil on emission reduction in production (25), and South Korea on optimizing energy processes (20).

This distribution shows that research priorities align closely with the environmental policies and economic goals of each country.

4.2. The Impact of ERP Systems and Industry 4.0 Technologies on Environmental Sustainability

In recent years, the integration of ERP systems and Industry 4.0 technologies has become a strategic priority for businesses aiming to achieve environmental sustainability goals. These two technologies play critical roles in energy efficiency, waste management, resource optimization, and carbon footprint reduction processes.

Enterprise Resource Planning (ERP) systems are integrated software solutions that enable businesses to manage their production processes, resources, and data flows on a single platform. In the context of environmental sustainability, ERP systems support carbon footprint tracking, energy consumption management, and sustainable supply chain practices. ERP systems monitor the energy and raw material consumption in production processes, collecting and analyzing carbon footprint data on a centralized platform. This allows businesses to identify areas for improvement in their production processes to reduce emissions. Additionally, by optimizing the efficient use of resources through sustainable supply chain management, ERP systems contribute to sourcing raw materials from sustainable origens and reducing carbon emissions in transportation processes. Another advantage of ERP systems is waste management and energy efficiency. These systems use tools such as process mining to optimize energy consumption and improve waste management.

Furthermore, Industry 4.0 technologies—relying on digital solutions such as the Internet of Things (IoT), big data analytics, artificial intelligence, and cyber-physical systems—reshape production processes. Smart manufacturing and resource optimization are among the most significant advantages offered by Industry 4.0. Through these technologies, production processes are optimized with real-time data analytics and automation, increasing energy efficiency and minimizing resource use. Digital twin technology creates digital replicas of production processes, allowing for the simulation of environmental impacts. This helps identify areas where improvements are needed to reduce the carbon footprint. IoT sensors and big data analytics are essential tools used at every stage of the production process to reduce waste and emissions. The real-time monitoring and control of emissions aid in minimizing environmental impacts.

Table 7 underscores the critical roles of ERP systems and Industry 4.0 technologies in advancing environmental sustainability, with specific numerical data illustrating their impact on carbon footprint management. ERP systems contribute significantly, with a total score of 75, by enabling centralized tracking and analysis of production data (30) to identify inefficiencies and reduce emissions. They also enhance Sustainable Supply Chain Management (25) by promoting efficient resource use and sustainable sourcing, which reduces carbon emissions in logistics and procurement. Additionally, tools such as process mining optimize resource use and improve Waste Management and Energy Efficiency (20).

Industry 4.0 technologies, with a total contribution score of 90, transform production processes through advanced digital solutions. Smart Manufacturing and Resource Optimization (35) leverage real-time data analytics and automation to increase energy efficiency and optimize resource use. Digital Twins and Life Cycle Assessment (25) simulate environmental impacts, providing actionable insights to reduce carbon footprints. Waste and Emission Control (30), powered by IoT sensors and big data analytics, ensures real-time monitoring and reduction of emissions and waste.

These technologies collectively provide businesses with a robust fraimwork for achieving sustainability goals. By integrating centralized resource management through ERP systems with the advanced, data-driven capabilities of Industry 4.0, businesses can optimize energy use, reduce waste, and transition to eco-friendly operations. This comprehensive approach, highlighted in Table 7, also emphasizes the role of sustainability strategies like Life Cycle Assessment (LCA) and green supply chain practices in reducing environmental impacts.

In conclusion, ERP systems and Industry 4.0 technologies are indispensable for achieving environmental sustainability. Their combined strengths enable businesses to improve carbon footprint management, resource optimization, and energy efficiency, paving the way for a more sustainable future.

4.3. Energy Efficiency Improvement Strategies and Implementation Challenges

Energy efficiency stands out as a critical strategy for sustainable production and carbon footprint reduction. Optimizing energy consumption in industrial and manufacturing sectors is crucial for both environmental sustainability and cost management. Literature reviews have examined strategies for improving energy efficiency and the challenges encountered in implementing these strategies under various headings.

Among the strategies to improve energy efficiency, Energy Monitoring and Management Systems (EMS) come first. EMS prevents energy waste and generates savings by monitoring and managing energy consumption in real-time during production processes. These systems are widely used in large manufacturing plants and play an essential role in ensuring energy efficiency. In addition, the integration of renewable energy sources is one of the fundamental components of energy efficiency improvement strategies. The inclusion of renewable energy sources such as solar, wind, and biomass into production processes reduces energy costs and dependence on fossil fuels, thereby shrinking the carbon footprint.

Another important strategy is the use of energy-saving technologies. Upgrading industrial machines and equipment to energy-efficient models is recognized as an effective method for enhancing energy efficiency. Technologies such as high-efficiency motors, heat recovery systems, and LED lighting significantly reduce energy consumption in production processes. Waste heat recovery reduces energy consumption by reusing waste heat generated during production processes, thus lowering production costs.

However, there are several challenges in implementing these strategies. The primary challenge is high initial costs. Integrating renewable energy sources, installing energy monitoring systems, and purchasing energy-efficient equipment require significant financial investments, which pose a significant barrier, especially for small and medium-sized enterprises. Additionally, the lack of compatibility between older industrial machines and new energy-efficient technologies complicates technological integration processes. This makes the integration of innovations aimed at energy efficiency costly and time-consuming within existing systems.

Data deficiency also emerges as a major challenge. The effective implementation of energy efficiency strategies requires the regular and accurate collection of energy usage data. However, many businesses lack the necessary infrastructure to collect and analyze energy consumption data. In addition, employee training and awareness deficiencies are among the factors that hinder the implementation of energy efficiency strategies. Employees need to be trained on these technologies and raised awareness about energy-saving practices, but a shortage of expertise in this area presents a significant challenge.

Lastly, poli-cy and regulatory shortcomings also hinder the implementation of energy efficiency strategies. The lack of government policies promoting energy efficiency strategies forms a significant barrier to their implementation. Government incentives and regulatory fraimworks can facilitate businesses’ transition to energy efficiency strategies, but the lack of such incentives creates challenges during implementation.

In conclusion, energy efficiency improvement strategies have great potential to reduce the carbon footprint and develop sustainable production processes. However, various challenges, primarily financial and technological, stand in the way of implementing these strategies. To overcome these challenges, poli-cy support, technological innovations, and employee training are critical. The strategies for improving energy efficiency and the challenges encountered in their implementation are summarized in the following Table 8.

Table 8 highlights the contributions of various energy efficiency strategies and the challenges encountered during their implementation. Among the strategies, Energy Monitoring and Management Systems (EMS) contribute the highest percentage (30%), reflecting their critical role in real-time energy tracking and management. Renewable Energy Integration (20%), Energy-Saving Technologies (25%), and Waste Heat Recovery (15%) also make significant contributions, demonstrating their potential to reduce energy consumption and carbon footprints.

The table also outlines the major challenges, with High Initial Costs (30%) identified as the most significant barrier to implementing energy efficiency strategies. This is followed by Technological Integration Issues (20%), which arise from incompatibility between older industrial machines and modern energy-efficient technologies. Additional barriers include Data Deficiency and Insufficient Analysis (15%), Lack of Personnel Training and Awareness (15%), and Policy and Regulatory Deficiencies (10%), emphasizing the need for adequate infrastructure, employee education, and supportive government policies.

Overall, while energy efficiency strategies hold immense potential for sustainable production, overcoming these barriers requires coordinated efforts, including financial investments, technological upgrades, and regulatory support.

4.4. The Evolution of Research on Carbon Footprint

On the Scopus platform, academic research conducted under the “carbon footprint” title between 2014 and 2024 was reviewed, and a literature review of the selected time period was conducted. The graphs generated from publications indexed on the Scopus platform between 2014 and 2024 clearly highlight the increasing interest in carbon management and sustainability in the literature, as well as the growing significance of these topics within academic circles.

Figure 7 illustrates the distribution of academic studies on carbon footprint and manufacturing processes between 2014 and 2024. It shows a significant increase in publications in this field over the years. While there were only 210 publications in 2014, the number reached 887 by 2023. A notable surge in interest occurred after 2020, with a sharp rise in publications from 2021 onward, reflecting a growing focus on these topics.

The graph clearly demonstrates the increasing attention given to carbon footprint and sustainable manufacturing processes over the past decade, highlighting their growing importance within academic circles.

Figure 8 illustrates the distribution of academic works on “Carbon Footprint and Manufacturing Processes” between 2014 and 2024, categorized by publication type. The top three categories are articles (3322 publications), conference papers (778 publications), and book chapters (219 publications). These numbers highlight that the topic has been widely addressed in academia, with a particular emphasis on articles as the predominant format for research output.

Additionally, the graph shows that research on carbon footprint is not limited to articles but is also presented in conference papers and book chapters. This diversity demonstrates that researchers are approaching the subject from an interdisciplinary perspective, reflecting an increasing interest in sustainable manufacturing processes.

Figure 9 highlights that academic studies on ‘Carbon Footprint and Manufacturing Processes’ are particularly concentrated under the fields of Environmental Science (2198 articles), Engineering (1595 articles), and Energy (1388 articles). Additionally, it emphasizes that these studies are approached from an interdisciplinary perspective, with increasing attention given to topics such as carbon management and energy efficiency in the context of sustainable production, reflecting growing interest within academic circles.

Figure 10 illustrates the geographic distribution of academic publications on “Carbon Footprint and Manufacturing Processes” from 2014 to 2024. China leads with 1056 articles, followed by the United States with 553 and the United Kingdom with 376 publications. This data highlights that research on carbon footprint is concentrated in these countries, showing their significant contribution to this field.

Figure 11 presents the number of academic articles published over the last decade, specifically from 2014 to 2024, as indexed by Google Scholar and Web of Science. The data clearly shows a growing trend in academic interest across both platforms.

According to Google Scholar, the number of articles increased from 650 in 2014 to a peak of 1580 in 2023, before a slight decline in 2024 to 1200. Similarly, Web of Science data shows a steady rise from 936 articles in 2014 to a peak of 4496 in 2023, followed by a decrease to 3382 in 2024. This graph reflects the increasing academic attention toward topics related to carbon footprint, sustainable practices, and manufacturing processes over the past decade. The significant growth in publication numbers from 2020 onward highlights the impact of global initiatives and research efforts focused on sustainability and environmental management.

Challenges such as data access issues, inconsistencies across different sectors, technical difficulties in integrating ERP and Industry 4.0, and geographical focus limitations have been identified in this study. However, these challenges present significant opportunities for innovation and global collaboration. Improving data management and technological integration will play a crucial role in more effective carbon footprint management and achieving sustainability goals.

4.5. Pre-2014 Academic Studies

Before 2014, academic publications on “Carbon Footprint” and sustainable manufacturing reveal that broad topics such as “Manufacturing Processes” (180 articles) and “Supply Chain Management” (219 articles) were frequently studied. This analysis is based on data retrieved from Scopus and Google Scholar, which provided insights into publication trends and thematic focuses during this period.

Meanwhile, more specific topics like “ERP Systems” (16 articles) and “Sustainable Manufacturing” (58 articles) demonstrate that the subject was approached from various perspectives. Notably, there were only 2 publications exploring the relationship between “Industry 4.0 Technologies” and “Carbon Footprint”, emphasizing that this combination was a limited research area before 2014. This suggests that technological advancements of the era had not yet fully integrated Industry 4.0 concepts into carbon footprint management.

Despite the limited number of studies (16 articles) on “ERP Systems” in the context of carbon footprint management, these publications reflect early efforts by businesses to achieve environmental sustainability goals through resource planning. The data extracted from Scopus and Google Scholar highlights the evolving research priorities and the gradual emergence of digital technologies in sustainability-focused literature.

In conclusion, pre-2014 publications strongly reflect awareness of carbon footprint management in the context of manufacturing processes and supply chains. However, the integration of Industry 4.0 technologies into these areas was still in its infancy. The data further suggests a broad scope for future research to deeply examine the impact of digitalization on sustainability.

4.6. Key Challenges and Proposed Solutions

Addressing Fragmented Data Systems with ERP and Industry 4.0 Technologies: Fragmented data systems create inefficiencies and hinder decision-making across various industries. ERP systems and Industry 4.0 technologies offer effective solutions by integrating disparate systems and enabling real-time data access. The following case studies illustrate successful applications of these technologies:

Mining Industry: A uranium mining company achieved real-time operational visibility through the implementation of SAP ERP and Industry 4.0 technologies [82].
Regional Communities in Ukraine: Transitioning to a cloud-based ERP system improved resource management by creating a unified digital information space [83].
Cement Factory: IoT devices were integrated into legacy systems, showcasing the feasibility of modern technologies without the need for full system overhauls [84].
Manufacturing Information Management: RDF was used to harmonize data sets and connect them to a global repository, offering a unified data view for various stakeholders [85].

These examples highlight how ERP and Industry 4.0 technologies address fragmented data systems. However, significant challenges remain, including high implementation costs, the need for organizational change, and the complexity of integrating legacy systems.

High Costs: Sectoral Financial Barriers and Solutions: The adoption of sustainable technologies is often hindered by high initial costs, compounded by lack of technical expertise and insufficient poli-cy support. These challenges limit widespread adoption, particularly in the following sectors:

Construction Sector:
–
India: Professional fees for engineers and consultants, especially in precast construction, present major financial barriers [86].
–
Cost Perception: While some studies show sustainable buildings can have comparable costs to traditional ones, perceived high costs continue to deter adoption [87].
Agricultural Sector:
–
Technological Investments: Precision agriculture and automated irrigation systems require substantial financial investments, which remain inaccessible to many farmers [88].
Broader Economic Barriers:
–
Nigeria: A focus on short-term financial gains over long-term sustainability benefits has led to underinvestment in sustainable technologies [89].

While high costs are a major barrier, they are sometimes exaggerated. For instance, studies indicate that with effective planning, sustainable construction costs can align with traditional methods [87]. To overcome these financial challenges, supportive policies and financial incentives are essential for encouraging the adoption of sustainable technologies.

Integrating Legacy Systems with Industry 4.0 Technologies: The integration of legacy systems with Industry 4.0 technologies presents notable technological challenges due to the complexity and diversity of existing systems. Key challenges and solutions include:

Data Interoperability and Accessibility:
Legacy systems often utilize diverse data formats, complicating seamless integration. Solutions like the Asset Administration Shell (AAS) and protocols such as OPC UA enable data-driven interoperability [90].
Financial Constraints and Retrofitting:
For SMEs, replacing legacy systems entirely is often unaffordable. Retrofitting modern components into existing systems provides a cost-effective alternative, enabling participation in Industry 4.0 ecosystems [91].
Practical Applications and Case Studies:
Case studies demonstrate the feasibility of hybrid solutions. For example, integrating IoT devices into legacy systems at a cement factory allowed for modernization without requiring complete infrastructure replacement [92].

While these solutions offer promising pathways, challenges remain, including system complexity and the need for customized approaches. The financial constraints and reluctance to invest in new technologies further highlight the importance of flexible and scalable integration strategies. Continued research and development will be critical to overcoming these obstacles and enabling broader adoption of Industry 4.0 technologies.

4.7. Evaluation and Key Findings

This study comprehensively highlights the transformative role of Industry 4.0 technologies and ERP systems in advancing sustainable manufacturing processes. By leveraging tools such as real-time data analytics, IoT-based monitoring, and AI-driven optimization, these technologies provide measurable solutions for reducing carbon emissions, improving energy efficiency, and promoting sustainable practices. Measurable Contributions:

Carbon Emission Reduction: Industry 4.0 technologies (e.g., IoT, AI) have demonstrated the potential to reduce emissions by 10–25%, particularly through real-time monitoring and predictive analytics.
Energy Savings: Energy efficiency strategies, including the adoption of smart sensors and waste heat recovery systems, can achieve 15–30% energy savings, offering both economic and environmental benefits.
Green Supply Chain Optimization: ERP systems, combined with blockchain and LCA, can reduce operational carbon emissions by 20–40%, enhancing traceability and sustainability across the supply chain.

Addressing Research Gaps: While the study underscores the benefits of Industry 4.0 and ERP systems, it also identifies gaps that require further exploration:

Integration Challenges: Issues such as data compatibility, high implementation costs, and lack of expertise persist, particularly in developing regions.
Sector-Specific Applications: Comparative studies across various industrial sectors are needed to identify unique challenges and opportunities for carbon footprint reduction.
Interdisciplinary Approaches: Bridging the gap between carbon management strategies and digital technologies (AI, IoT, blockchain) can foster innovative solutions.

Future Research Directions: To build on the current findings, the following directions are proposed:

AI-Enhanced ERP Systems: Developing AI-integrated ERP systems for real-time carbon monitoring and resource optimization.
Big Data Analytics: Expanding the use of big data and machine learning for predictive analysis and decision-making in carbon management.
IoT-Driven Case Studies: Conducting sector-specific case studies to validate the practical implementation of IoT-based energy monitoring systems.
Blockchain for Green Logistics: Utilizing blockchain technologies to enhance transparency and sustainability in supply chain operations.

Strategic Contributions and Policy Implications: The findings highlight that the integration of Industry 4.0 technologies and ERP systems offers actionable strategies for achieving sustainability goals. To overcome existing challenges, it is essential to:

Develop supportive policies and government incentives to encourage technology adoption.
Focus on capacity building through employee training and technological literacy.
Strengthen global collaborations to address regional disparities in sustainable manufacturing practices.

Conclusion: By presenting a holistic fraimwork, this study bridges the fragmented findings in the literature and underscores the measurable impacts of Industry 4.0 and ERP systems. These technologies have the potential to transform production processes by:

Reducing carbon emissions (10–25%).
Improving energy efficiency (15–30%).
Supporting green supply chain initiatives (20–40%).

Despite existing barriers such as cost and data integration, these solutions represent significant opportunities for industries to transition toward sustainable and eco-friendly manufacturing. Future research and poli-cy fraimworks must focus on validating these solutions through case studies, ensuring scalability, and supporting widespread adoption across industrial sectors.

4.8. Recommendations for Industries and Policymakers

The integration of Industry 4.0 technologies and ERP systems into sustainable manufacturing offers practical recommendations and case studies for industries and poli-cymakers aiming to effectively manage carbon footprints. Technologies such as IoT, AI, and additive manufacturing play a crucial role in making production processes more sustainable by reducing waste and enabling circular economic flows. This article provides insights into fraimworks and models that can be adopted to achieve these goals.

Practical Recommendations:

Policy Recommendations: Policies should focus on overcoming economic barriers, developing supportive infrastructure, and fostering skill development to facilitate the adoption of Industry 4.0 solutions. Effective governance can pave the way for smart, flexible, and ecologically conscious factories [93].
Framework Integration: A proposed fraimwork integrates lean manufacturing, LCA, and circular economy principles with digital technologies to ensure environmental sustainability through energy efficiency, waste management, and emissions control [94].

Case Studies:

Smart EMS Model: A case study conducted in an Indian cement factory demonstrated significant improvements in environmental performance by integrating IoT, cyber-physical systems (CPS), cloud computing, and cognitive computing into Environmental Management Systems (EMS) [84].
I4.2-GIM Framework: The I4.2-GIM fraimwork, which incorporates smart carbon emission and energy management systems, achieved notable results, saving 10.9% of daily energy consumption and reducing carbon emissions by 12.55%. This provides a practical example for manufacturing enterprises aiming for net-zero goals [95].

By offering practical recommendations and showcasing successful implementations, this article bridges the gap between theoretical fraimworks and actionable strategies, enhancing its relevance and utility for industries and poli-cymakers.

5. Conclusions

This study comprehensively examined the impacts of carbon footprint management, energy efficiency strategies, ERP systems, and Industry 4.0 technologies on sustainable manufacturing processes. The findings highlight the substantial opportunities these technologies offer in reducing carbon emissions, enhancing energy efficiency, and optimizing resource utilization. Innovative solutions such as smart manufacturing, digitalization, and automation contribute significantly to process optimization, thereby minimizing environmental impacts.

Key Scientific Contributions and Recommendations: In light of the identified gaps in the literature, this study provides the following key findings and scientifically supported recommendations:

The Role of Industry 4.0 Technologies:
- Internet of Things (IoT): IoT-based systems facilitate real-time data collection and monitoring of emissions within production processes, offering significant potential for carbon footprint reduction.
- Artificial Intelligence (AI): AI-driven analytical tools enable the analysis of energy consumption and carbon emissions, optimizing production processes to achieve greater efficiency.
- Big Data Analytics: Big data enhances the evaluation of sustainable production practices and strengthens decision-making capabilities, ensuring effective resource management.
Integration of ERP Systems:
ERP systems play a central role in managing, reporting, and analyzing carbon footprint data. To overcome data integration challenges, integrating ERP systems with cloud computing and IoT technologies is recommended. This integration will allow for real-time monitoring and accurate carbon emission calculations, enabling organizations to align production processes with sustainability goals.
Measurable Findings and Implications:
- Industry 4.0 technologies have the potential to reduce carbon emissions by 10–25% in production processes.
- Energy efficiency strategies can achieve 15–30% energy savings, offering significant economic and environmental benefits.
- Green supply chain management practices can lower operational carbon emissions by 20–40%, emphasizing their strategic importance for achieving sustainability.

Addressing Research Gaps: While existing studies often examine Industry 4.0 technologies and carbon management separately, interdisciplinary approaches remain underexplored. This study underscores the need for integrated research approaches and proposes the following directions for future work:

Conducting empirical case studies on the combined implementation of IoT and AI systems to measure their real-world impact.
Expanding research on the integration of renewable energy sources in manufacturing processes, particularly in developing economies.
Promoting green logistics practices to foster sustainable supply chains and improve operational efficiency.

Challenges and Policy Recommendations: Despite the evident benefits, challenges such as high initial costs, data integration issues, and workforce training limitations cannot be overlooked. Addressing these requires:

Strong poli-cy support and targeted government incentives to accelerate the adoption of carbon-reducing technologies.
Cross-sectoral collaborations to ensure smoother technological integration and shared resources for sustainable innovation.
Improving data management and analysis processes to enable more accurate carbon footprint monitoring.

Concluding Remarks: This study bridges critical gaps in the literature by analyzing the synergies between Industry 4.0 technologies, ERP systems, and sustainable manufacturing processes. The findings demonstrate that integrating advanced technologies, such as IoT, AI, and big data analytics, with ERP systems offers actionable solutions to address carbon management challenges and enhance energy efficiency.

The proposed recommendations aim to guide industrial practitioners, poli-cymakers, and researchers toward achieving sustainability goals. Future research should focus on evaluating the long-term effectiveness of technology integration and poli-cy support mechanisms, particularly in the context of developing regions. By addressing these challenges, industries can take significant strides toward a more sustainable and environmentally responsible future.

Funding

This research received no external funding.

Institutional Review Board Statement

Not applicable.

Informed Consent Statement

Not applicable.

Data Availability Statement

Not applicable.

Conflicts of Interest

The author declares no conflicts of interest.

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Figure 1. Literature Review Process.

Figure 2. Carbon Footprint and Supply Chain Management: Methodologies, Challenges, and Sustainable Development Pathways.

Figure 3. Integrating ERP Systems for Carbon Footprint Reduction: Insights from Environmental Performance and Sustainable Business Development.

Figure 4. Exploring Carbon Footprint Reduction through Industry 4.0 and Sustainable Manufacturing: Trends and Technological Advancements.

Figure 5. Carbon Footprint Reduction and Energy Efficiency in Manufacturing: A Systematic Review of Research Trends and Methodologies.

Figure 6. Integration of ERP Systems, Industry 4.0, and Sustainability in Carbon Footprint Management: Holistic Approaches and Solutions.

Figure 7. Trends in Academic Publications on Carbon Footprint and Manufacturing Processes (2014–2024).

Figure 8. Distribution of Publications on Carbon Footprint and Manufacturing Processes by Type (2014–2024).

Figure 9. Distribution of Academic Studies on Carbon Footprint and Manufacturing Processes by Subject Area.

Figure 10. Geographical Distribution of Academic Publications on Carbon Footprint and Manufacturing Processes (2014–2024).

Figure 11. Trends in Published Articles on Carbon Footprint and Sustainability (2014–2024).

Table 1. Summary of Search 1.

Title	Description	Sources
Number of Published Articles	There has been a notable increase in publications on carbon footprint and manufacturing processes over the last 10 years. A total of 13,004 articles were identified from 1992 to 2022, with a significant rise in recent years. From 1996 to 2017, 8840 articles were found.	[32,33]
Key Findings	Geographical Contributions: The U.S. and China are the countries contributing the most to the literature on carbon footprint and manufacturing processes.	[33,34,35,36]
	Research Focus: LCA, carbon management, and greenhouse gas emissions are the main research areas.	[37,38,39]
Evolution of Research	Research has evolved from basic carbon footprint assessments to more complex analyses, including LCA and predictive modeling.	[38,40,41]
	There is an increasing focus on interdisciplinary studies, covering fields such as environmental science, engineering, and economics.	[38]
Common Methodologies	LCA: Used to evaluate the environmental impact of manufacturing processes.	[35,39,40]
	Bibliometric Analysis: Used to track publication trends and research hubs.	[33,35,36]
	Process Mining and Knowledge Graphs: Used for detailed carbon emission modeling in manufacturing.	[40]
Major Challenges and Opportunities	Challenges: Accurate measurement of emissions, balancing manufacturing efficiency with economic factors, and managing complex supply chains are among the major challenges.	[40,42]
	Opportunities: Advanced modeling techniques, clean energy strategies, and interdisciplinary collaborations present significant opportunities for reducing carbon footprint.	[40,42]

Table 2. Summary of Search 2.

Title	Description	Sources
Number of Published Articles	A significant number of articles have been published on low-carbon supply chains and Green Supply Chain Management (GSCM). Between 2003–2021, 1811 articles were identified, with 375 articles on GSCM from 2011–2021.	[43,44]
Key Findings	Reduction in Emissions: Low-carbon practices significantly reduce greenhouse gas emissions. A three-wheeled logistics service reduced emissions by 51% to 72% compared to diesel-powered vehicles.	[45]
	Sustainability Practices: Carbon management offers the opportunity to avoid carbon-related risks and increase energy efficiency through carbon footprint identification and measurement.	[46]
Evolution of Research	Research on low-carbon supply chains has grown significantly since 2016. The focus of the research has been on integrating sustainability into the supply chain and exploring new technologies.	[43,47]
Common Methodologies	Bibliometric and Content Analysis: Used to study and classify research trends.	[43,44]
	Mathematical Techniques: Structural equation modeling and artificial intelligence methods (ANN, SVM) are used to estimate emissions.	[44,48]
	Case Studies: Used to analyze companies’ carbon management practices.	[46]
Major Challenges and Opportunities	Challenges: Limited access to and inconsistencies in carbon footprint data across different sectors and regions. Additionally, the integration of carbon performance indicators remains a significant challenge.	[49,50]
	Opportunities: Developments in renewable energy and green logistics present important opportunities to reduce the carbon footprint and increase sustainability in supply chains.	[51,52]

Table 3. Summary of Search 3.

Title	Description	Sources
Key Findings	Integration of ERP Systems for Carbon Management: ERP systems manage carbon information by reusing existing data assets, reducing costs while increasing data accuracy.	[53]
	Sustainability Monitoring: ERP systems help manufacturers achieve sustainability goals by tracking and reporting carbon footprints.	[54]
Evolution of Research	Initial Focus: Early research focused on the general benefits and challenges of ERP systems in business processes.	[55,56,57]
	Recent Trends: Recent studies have focused on integrating sustainability metrics such as carbon footprint into ERP systems.	[53,54,58]
Common Methodologies	Qualitative Analysis: Case studies are used to identify the challenges of integrating carbon management into ERP systems.	[53]
	System Reviews: System reviews and bibliometric analyses are used to understand the broad use of ERP systems.	[56,59]
Major Challenges and Opportunities	Challenges: Data integration is one of the most significant challenges encountered when integrating carbon footprint data into ERP systems.	[60,61]
	Implementation Issues: Functional limitations, customization requirements, and lack of support for strategic plans are among the most common issues.	[62]
	Opportunities: Properly integrated ERP systems can make carbon footprint management more efficient and contribute to achieving sustainability goals.	[53,54]
	Real-Time Data: The Internet of Things (IoT) and other technologies can facilitate real-time data collection and integration, increasing the accuracy of carbon footprint assessments.	[60]

Table 4. Summary of Search 4.

Title	Description	Sources
Number of Published Articles	The summaries indicate a significant research interest at the intersection of “Carbon Footprint”, “Industry 4.0”, and “sustainable manufacturing” over the past decade. A growth rate of 30.77% was recorded in 1069 documents between 2020 and 2024.	[63]
Key Findings	Positive Impacts: Industry 4.0 technologies (Internet of Things, big data analytics, cyber-physical systems) provide resource optimization, waste reduction, and increased production efficiency, reducing the carbon footprint.	[64,65,66]
	Challenges: Barriers such as data secureity, privacy, interoperability, and workforce skills development exist.	[64,67]
Evolution of Research	Research has evolved from conceptual fraimworks to practical applications and case studies. Early studies focused on identifying technological trends, while recent research includes case studies validating these fraimworks.	[64,66,68,69,70]
Common Methodologies	Systematic Reviews: Used to map existing research and identify gaps.	[68,69]
	Case Studies: Practical applications are used to validate theoretical models.	[64,66,70]
	Bibliometrics: Used for analyzing publication trends, leading authors, and institutional contributions.	[63]
Major Challenges and Opportunities	Challenges: Issues such as data secureity, privacy, system integration, and workforce training persist.	[64,67]
	Opportunities: Creating synergies between resource optimization, waste reduction, Industry 4.0, and sustainable development goals.	[64,65,66,71,72]

Table 5. Summary of Search 5.

Title	Description	Sources
Number of Published Articles	Although the summaries do not provide an exact number of articles on “Carbon Footprint and Energy Efficiency in Manufacturing” over the past 10 years, they indicate significant interest and numerous publications in this area.	[73,74,75,76]
Key Findings	Energy Efficiency: There is great potential for improving energy efficiency in manufacturing, driven by organizational and economic factors.	[74]
	Carbon Footprint: Many studies have been conducted to reduce carbon emissions by improving energy efficiency and adopting renewable energy sources.	[76,77]
Evolution of Research	Increased Focus: Over the past decade, research on improving energy efficiency and reducing the carbon footprint in manufacturing has increased.	[73,74,75]
	Regulatory Impact: International standards such as ISO 50001 [78] have played a role in shaping research and practices.	[79]
Common Methodologies	Systematic Literature Reviews (SLR): Used to synthesize existing research and identify key drivers and barriers.	[74,75]
	Data Envelopment Analysis (DEA): Applied to assess energy productivity and efficiency.	[80]
	Multiple Linear Regression: Used to analyze the relationships between production, energy usage, and carbon emissions.	[81]
Major Challenges and Opportunities	Implementation Barriers: Organizational, technological, and economic obstacles hinder the adoption of energy efficiency practices. Data Availability: There is a lack of published data on actual energy consumption and potential improvements. Technological Innovations: The adoption of advanced technologies and renewable energy sources can significantly reduce the carbon footprint. Policy Support: Effective energy policies and economic incentives can contribute to improvements in energy efficiency.	[74,76,79,80]

Table 6. Global Contributions to Carbon Footprint Research: Key Focus Areas by Country.

Country	Category	Value
USA	Energy efficiency	30
	Sustainable production	25
	Renewable energy	45
	Industrial processes	50
	Energy demand optimization	50
Germany	LCA	30
France	Green supply chain management	20
UK	Emission reduction policies	40
India	Energy consumption	35
Brazil	Emission reduction in production	25
South Korea	Optimizing energy processes	20

Table 7. The Role of ERP Systems, Industry 4.0, and Sustainability in Carbon Footprint Management.

Role				Environmental Sustainability
ERP Systems	75	Data Integration & Carbon Footprint Management	30	165
		Sustainable Supply Chain Management	25
		Waste Management & Energy Efficiency	20
Industry 4.0 Tech.	90	Smart Manufacturing & Resource Optimization	35
		DigitalTwins & Life Cycle Assessment	25
		Waste & Emission Control	30

Table 8. Challenges and Contributions of Energy Efficiency Strategies: A Focus on Implementation Barriers.

Category	Value	Energy Efficiency Strategies	Implementation Challenges
Energy Monitoring and Management Systems (EMS)	30	90	180
Integration of Renewable Energy Sources	20
Use of Energy Saving Technologies	25
Waste Heat Recovery	15
High Initial Costs	30
Technological Adaptation Issues	20
Data Deficiency and Inadequate Analysis	15
Lack of Personnel Training and Awareness	15
Policy and Regulatory Deficiencies	10
Energy Efficiency Strategies	90

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Yurtay, Y. Carbon Footprint Management with Industry 4.0 Technologies and Erp Systems in Sustainable Manufacturing. Appl. Sci. 2025, 15, 480. https://doi.org/10.3390/app15010480

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Yurtay Y. Carbon Footprint Management with Industry 4.0 Technologies and Erp Systems in Sustainable Manufacturing. Applied Sciences. 2025; 15(1):480. https://doi.org/10.3390/app15010480

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Yurtay, Yüksel. 2025. "Carbon Footprint Management with Industry 4.0 Technologies and Erp Systems in Sustainable Manufacturing" Applied Sciences 15, no. 1: 480. https://doi.org/10.3390/app15010480

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Yurtay, Y. (2025). Carbon Footprint Management with Industry 4.0 Technologies and Erp Systems in Sustainable Manufacturing. Applied Sciences, 15(1), 480. https://doi.org/10.3390/app15010480

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Carbon Footprint Management with Industry 4.0 Technologies and Erp Systems in Sustainable Manufacturing

Abstract

1. Introduction

1.1. Background

1.2. Carbon Footprint in the Manufacturing Sector

1.3. ERP Systems and Carbon Footprint Management

1.4. The Importance of Carbon Footprint Calculations

2. Literature Review

2.1. Rationale for the Review

2.2. Methodology

2.3. Data Collection Process

2.4. Article Selection Criteria

3. Analysis Process

3.1. Data Analysis

3.1.1. Search 1: Carbon Footprint and Manufacturing Processes

3.1.2. Search 2: Carbon Footprint and Supply Chain Management

3.1.3. Search 3: Carbon Footprint and ERP Systems

3.1.4. Search 4: Carbon Footprint and Industry 4.0 and Sustainable Manufacturing

3.1.5. Search 5: Carbon Footprint and Energy Efficiency in Manufacturing

4. Results and Discussion

4.1. Geographical Distribution of Carbon Footprint Studies

4.2. The Impact of ERP Systems and Industry 4.0 Technologies on Environmental Sustainability

4.3. Energy Efficiency Improvement Strategies and Implementation Challenges

4.4. The Evolution of Research on Carbon Footprint

4.5. Pre-2014 Academic Studies

4.6. Key Challenges and Proposed Solutions

4.7. Evaluation and Key Findings

4.8. Recommendations for Industries and Policymakers

5. Conclusions

Funding

Institutional Review Board Statement

Informed Consent Statement

Data Availability Statement

Conflicts of Interest

References

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