In the heart of Italy’s industrial district, Philip Morris Manufacturing & Technology Bologna (PMMTB), is an emerging leader in sustainable transformation.
PMMTB is comprised of two distinct sites in the Emilia-Romagna region of Italy: The Crespellano site and the Zola Predosa site. Crespellano is PMI’s first global facility dedicated to large-scale production and export of smoke-free products. Zola Predosa, meanwhile, is home to the Philip Morris Training Center, which supports large scale production of smoke-free tobacco products and employee training—driving innovation and capability building. PMMTB serves both as a manufacturing leader and a hub for industrial learning and development.
Through strategic investments under PMI’s Drive for Zero and Zero Carbon Tech programs, the company is redefining industrial decarbonization—starting with a bold expansion of photovoltaic (PV) technology to reduce Scope 1 and Scope 2 emissions.
From compliance to leadership: The PV journey
In 2011, regulatory developments in Italy supported renewable energy integration in new industrial buildings, requiring a minimum of 0.5kW of PV capacity per 100m² of climatized surface.
This prompted PMMTB’s investment in renewable technology, resulting in an initial 400kW installation at its Bologna site, meeting the initial regulatory requirement and laying the foundation for future innovation.
But PMMTB didn’t stop there. Its initial approach quickly evolved into a broader climate leadership strategy.
Recognizing solar energy’s potential, PMMTB redesigned the factory roof to accommodate additional panels.
Today, the site boasts an impressive 8.2MW of installed PV capacity—more than 20 times the original requirement. The transformation is so striking that passengers landing at Bologna Airport can see the solar-covered roof from above.
Over the past five years, two complementary programs under PMI’s Climate Transition Plan have driven CO₂ emissions reductions: Drive 4 Zero (D40), which focuses on operational efficiency and emissions reduction across manufacturing; and Zero Carbon Tech (ZCT), which accelerates the adoption of advanced technologies and renewable energy sources.
Image: Employee in a factory
Defining success: More than just megawatts
For PMMTB, success is multidimensional. The PV expansion has:
- Reduced CO₂ emissions across Scope 1 and 2: Scope 2 reductions were achieved through renewable electricity generation, while Scope 1 reductions were enabled by pairing this renewable energy with heat pumps and electric boilers.
- Improved energy efficiency and strengthened business resilience.
- Proven financially sound—with the PV system projected to provide reliable cash flow for more than 25 years through lower energy costs.
The initiative—the first of its kind in a PMI factory—now serves as a model for replication, inspiring similar PV projects across sites worldwide, including Greece, Lithuania, Mexico, Philippines, Portugal, Romania, and Türkiye. This demonstrates both its scalability and PMMTB’s leadership in low-carbon innovation.
Heat pumps and hybrid systems: Building resilience
Complementing the PV rollout, PMMTB has also invested in heat pump technologies, with a total installed capacity of 4MW across seven units—one water-to-water and six air-to-water. They are paired with two electric boilers, providing an additional 10MW of capacity.
Together, these systems support PMMTB’s decarbonization strategy. They help significantly reduce Scope 1 and Scope 2 emissions while offering dual-fuel flexibility, allowing PMMTB to adapt to energy price volatility and maintain operational continuity.
Altogether, the two large electric boilers and heat pumps are capable of reducing up to 13,000 tons of direct CO₂ emissions. Powered by electricity rather than fossil fuels, they are complemented by photovoltaic panels that generate clean energy at PMMTB’s Crespellano site, helping to balance their added electricity need.
At the Zola Predosa site, PMMTB applied a similar electrification strategy, installing an innovative steam-producing heat pump that reuses process heat from the production line. This first-of-its-kind system captures waste heat and channels it through a state-of-the-art steam-producing heat pump. This breakthrough project enables the site to reduce the primary fossil steam demand by 40-50 percent, while recovering 30 percent of water from the exhaust. The project serves as a pilot to further explore technologies that can contribute to PMI’s net-zero and efficiency targets.
Zola Predosa is also equipped with standard solar PV systems, along with innovative applications—such as walking-path panels and thin-film carbon-based units installed vertically on the back of the factory—showcasing how solar can be seamlessly integrated into industrial design.
Beyond emissions reductions, these investments have enhanced energy reliability and stabilized factory processes, reducing both breakdowns and energy consumption. Employees have also expressed pride in the company’s environmental leadership, while “lean” manufacturing practices have further improved process efficiency and predictability.
Beyond the fence line: Community and corporate equity
“This project is a clear example of how sustainability can drive industrial reinvention,” said Giorgio Santoni, Manager of Initiatives at PMMTB. “We didn’t just meet regulatory requirements—we reimagined what a factory can be.
“By integrating solar energy and electrification at scale, we’ve created a model that is not only efficient and resilient, but also a benchmark for the local industrial ecosystem—demonstrating leadership through innovation, responsibility, and a long-term commitment to shared progress.” PMMTB’s sustainability journey has also strengthened its ties with the local industrial community. Through forums and knowledge-sharing events, the company has showcased its achievements, fostering collaboration and trust among neighboring businesses. This “intangible equity”—built on transparency and shared purpose—has become a cornerstone of PMMTB’s identity.
Image: Philip Morris Manufacturing & Technology Bologna
Looking ahead: Designing for sustainability
Lessons learned from PMMTB’s existing operations help to shape future strategies. Climate adaptation is now embedded in business continuity planning, and sustainability investments are increasingly viewed as strategic enablers rather than costs.
By eliminating inefficiencies and embedding strong governance systems, PMMTB ensures that technical investments deliver lasting value.
This market story should be read in conjunction with Integrated Report 2024 and the 2024 FY actuals for selected EHS data:
Stories of Impact
How PMB is powering low-carbon progress
Discover how PMI’s affiliate in Brazil has embedded climate action through strategic planning and daily operations.
Philip Morris Mexico: Driving climate action beyond the fence line
How PMI’s affiliate in Mexico is delivering climate action through a targeted focus on manufacturing and distribution, coupled with meaningful local engagement on renewable infrastructure.
Turning smoke-free consumables waste into opportunity in Egypt
Discover how Philip Morris Misr is helping shape a culture of responsibility and innovation through post-consumer waste programs.