Leading with Electrification: Setting New Sustainability Standards

By Nickyle Milton

In the heart of the Dallas-Fort Worth metroplex, Siemens’ Grand Prairie, TX, manufacturing plant is not only producing critical low-voltage power equipment but also redefining how powder coating can contribute to decarbonization. The site’s latest innovative deployment, a fully electric powder coating line, reflects the company’s larger push toward sustainability, innovation, and operational efficiency.

The Siemens Grand Prairie facility, which opened in the mid-1990s and expanded significantly in 2016–2017, now spans approximately 249,000 square feet. It manufactures 480-volt switchboards and switchgear for industrial applications—products vital to infrastructure and construction markets worldwide. As part of Siemens Smart Infrastructure USA’s Electrical Products business unit, this plant has become a beacon for sustainable manufacturing practices in the company’s global operations.

Overhauling a Carbon Emitter
One of the most significant upgrades in recent years has been the complete overhaul of its aging powder coating process. The previous system, which had been in place for over 30 years, was identified as a major source of carbon emissions at the site. In fact, a 2018 emissions study found that the old paint line contributed to between 70% and 80% of the factory’s carbon output. Faced with this data, Siemens made a strategic decision to transform how it approached surface finishing, focusing on decarbonization and electrification.

This transformation culminated in the installation of a 1,300-foot-long, all-electric powder coating line that processes both cold-rolled and hot-rolled steel. Running at a speed of 16 feet per minute, the new line incorporates automatic paint booths, a zirconium-based pretreatment system, and infrared boost technology for curing. The shift from phosphate to zirconium pretreatment not only eliminates certain hazardous substances from the process but also aligns with Siemens’ broader sustainability goals. Zirconium offers reduced energy consumption and improved environmental safety, making it a smart alternative for modern powder coating systems.

Eliminating natural gas from the powder coating process was a central objective. By transitioning to electric- based systems and incorporating renewable energy credits (RECs), Siemens achieved a dramatic reduction in emissions. Since the installation of the new line, the Grand Prairie plant has recorded a decrease of approximately 1,100 metric tons in net carbon emissions. This represents more than 90% of the site’s production-related, natural gas-based CO₂ emissions. While electricity usage has understandably increased, Siemens has taken steps to monitor and manage this growth through advanced water and electricity metering systems.

Another logistical hurdle was ensuring the site’s electrical infrastructure could support the added load from the all- electric system. Siemens worked closely with Oncor, the local utility provider, to assess and prepare for increased power demands. Actual power consumption was lower than projected, providing even more energy savings than anticipated.

Embracing a Sustainability Ethos
Beyond emissions reductions and energy efficiency, the powder coating line also supports Siemens’ strategic sustainability framework known as DEGREE. This framework outlines the company’s environmental, social, and governance (ESG) targets across six core pillars: decarbonization, employability, governance, resource efficiency, equity, and ethics. Siemens' actions in Grand Prairie directly address these pillars by reducing reliance on fossil fuels, improving resource utilization, and promoting long-term environmental stewardship.

Siemens’ DEGREE framework is more than an internal set of goals. It is also a tool for empowering customers to meet their own sustainability targets. Because Siemens products are integral to customer infrastructure, improvements at the Grand Prairie plant ripple outward. Customers now benefit from a supply chain that has taken concrete steps to reduce its carbon footprint. As a result, doing business with Siemens becomes a more environmentally responsible choice, particularly for organizations with strict ESG requirements.

The Grand Prairie project has also become a model for other Siemens facilities. A similar paint line is being scaled at the company’s Fort Worth location, and plans are in motion for replication at the Pomona, CA, plant within the next two years. Internationally, Siemens’ global teams are closely watching the Texas operation for insights into how to implement similar technologies elsewhere.

The innovation extends beyond electrification. Siemens is currently collaborating with its suppliers to identify ways to reduce the energy required to produce quality powder coated parts. These efforts are part of a broader initiative to improve process efficiency while maintaining the high standards Siemens is known for in industrial applications.

While the technical details of this project are compelling, its broader implications are equally significant. The installation of the all-electric powder coating line positions Siemens not only as a manufacturer but also as a sustainability leader in the industrial sector. The company has demonstrated that it is possible to significantly reduce emissions without sacrificing productivity, even in complex, high-volume manufacturing environments.

The line’s use of infrared boost curing is a key example. Unlike conventional curing methods that rely heavily on natural gas, infrared technology delivers heat directly to the coated surface, reducing overall energy consumption. Combined with a water- and electricity-metered control system, the facility can now fine-tune operational variables to maintain consistent quality while conserving resources.

The success of the Grand Prairie facility also underscores the importance of continuous improvement and long-term planning. Siemens did not simply replace outdated equipment; it reimagined how powder coating could function within a sustainable manufacturing environment. The company incorporated decades of operational experience and lessons learned to develop a system that supports both current production needs and future environmental targets.

Looking Ahead
In a sector where margins are tight and reliability is paramount, Siemens has shown that sustainability and performance are not mutually exclusive. By embracing electrification, deploying renewable energy credits, and refining its processes for energy and material efficiency, the company has created a new benchmark for powder coating operations.

As Siemens looks to the future, the Grand Prairie facility stands as proof that strategic investments in technology and infrastructure can yield measurable gains in environmental performance. The plant’s all-electric powder coating line exemplifies how innovation and sustainability can coexist, offering a clear path forward for manufacturers seeking
to reduce emissions while maintaining high production standards.

With facilities like Grand Prairie leading the way, the powder coating industry is poised to take meaningful steps toward a more sustainable future. And Siemens, through its commitment to decarbonization and digitalization, is well- positioned to lead that charge.

Nickyle Milton is change and technology manager at Siemens Smart Infrastructure USA.