Walking the talk: How Thermo King is putting circularity into action

Circularity is rapidly becoming one of the most important principles in sustainable manufacturing — and for good reason. Unlike the traditional “take‑make‑waste” linear model, circularity focuses on designing products, processes, and systems that keep materials in use for as long as possible. It’s about minimising waste, maximising resource efficiency, and extending materials’ lifecycles beyond a single use.

This isn’t just theory; global research shows that circularity is one of the most effective ways to reduce carbon emissions and protect finite resources. According to the United Nations Environment Programme (UNEP), circularity can reduce resource use by up to 28% globally and substantially decrease waste generation.

In a circular economy, products are designed to be repaired, reused, remanufactured, or recycled, creating ongoing value while reducing environmental impact. For Thermo King, circularity isn’t just a concept; it is personal— it’s one of the core pillars of Trane Technologies’ 2030 Sustainability Commitments and a powerful driver of innovation across our global operations.

Our initiatives in Barcelona, Galway, and our Remanufactured Parts program are prime examples of how we are boldly challenging what’s possible while creating sustainable growth.

Barcelona: Breathing New Life into Zip Ties

In our Barcelona facility, the team has embarked on a groundbreaking circularity project that transforms single-use plastic zip ties into high-value, closed-loop components. Each year, approximately 450,000 zip ties are generated throughout the production facility. Instead of discarding these plastics, the Barcelona Green Team found a way to repurpose them into new drain tubes for our refrigeration units.

How they did it

The team installed a shredding machine to break down used zip ties into plastic pellets. These pellets are then sent to a supplier, melted, and moulded into new PA6 drain tubes — a durable, wear-resistant material ideal for long-lasting refrigeration components.

The results

“Circularity keeps products, equipment, and infrastructure in use for longer, improving resource productivity,” explains the Barcelona Plant Manager.

This closed-loop process has delivered significant impact:

• Drain tube resin: 0% → 100% recycled content
• 4,300 kg CO₂e saved annually
• Equivalent to 10,953 miles driven or 4,778 pounds of coal burned

The initiative now serves as a scalable model for circularity across other Trane Technologies sites.

Galway: Accelerating Sustainable Operations

Our manufacturing team in Galway, Ireland, is at the forefront of Thermo King’s carbon-neutral operations. By implementing a multi-faceted carbon reduction strategy, the Galway team is significantly reducing Scope 1 and 2 carbon emissions, moving Thermo King closer to Trane Technologies’ 2030 Sustainability Commitment of carbon-neutral operations.

How they did it

The Galway team implemented a comprehensive mix of energy, materials, and process improvements, including:

• Switching from diesel to HVO biodiesel
• Using reusable dollies and crates
• Operating a carbon-neutral Advancer production line
• Installing 2,000 photovoltaic solar panels
• Upgrading roof insulation
• Transitioning to LED lighting across the facility

The results

These improvements have accelerated Galway’s sustainability performance:

• 29% reduction in total CO₂e emissions
• 99% reduction in Scope 1 diesel emissions
• 33% reduction in non-hazardous waste
• 1,000,000 kWh expected annual renewable energy generation
• €56,000 annual savings from LED upgrades
• Zero waste to landfill since 2014

Since becoming the first Trane Technologies site to achieve zero waste‑to‑landfill nearly a decade ago, Galway continues to lead with automation, robotics, electrification, and sustainable manufacturing innovation.

Remanufactured Parts Program: From Take, Make, Waste to Reduce, Reuse, Recycle

Our commitment to sustainability extends beyond our manufacturing processes. The Remanufactured Parts program exemplifies our dedication to a circular economy. Instead of discarding used parts, we remanufacture them, ensuring minimal resources are lost and discarded.

How they did it

Under this program, components from used controllers are salvaged and remanufactured into new, fully functional controllers. These remanufactured parts undergo rigorous testing to ensure the same quality as original factory-made controllers. This program not only reduces waste but also offers customers more affordable, genuine Thermo King controllers.

The results

The program delivers multiple circularity benefits:

• Keeps valuable materials in circulation
• Reduces landfill waste
• Lowers demand for virgin materials
• Provides cost-effective, high-quality alternatives for customers

Today, the program focuses on controllers. The next step — expanding into compressors — will deepen Thermo King’s commitment to resource efficiency and product life extension.

Circularity as a Strategic Advantage

Circularity is quickly becoming a defining differentiator for companies ready to lead in a low-carbon future. At Thermo King, our initiatives in Barcelona, Galway, and our Remanufactured Parts Program show how circular thinking can unlock real value — reducing emissions, extending product life, and strengthening operational resilience.

But the real opportunity is bigger: by integrating circularity into the core of how we design, build, and support our solutions, we can help transform the entire cold chain. As demand for sustainable, reliable temperature-controlled transport grows, circularity will shape the products and partnerships that define our industry.

For us, it’s simple: circularity isn’t just good for the planet — it’s a smarter way to innovate. And Thermo King is committed to leading the way.