Executive Summary

Mavarick partnered with an international plastics manufacturer with production in the UK and US to help transform their sustainability ambition into measurable, data-driven results. Recognising their goal of leading the way in sustainability while meeting market and regulatory demands, we provided advanced carbon emissions management and decarbonisation solutions tailored for the manufacturing sector.

Our AI-driven platform, combined with bespoke support, enabled the manufacturer to consolidate fragmented emissions data, establish a verifiable Organisational Carbon Footprint, and enhance internal capability. The result was a streamlined, scalable sustainability framework positioning them for long-term leadership in a low-carbon economy.

Understanding the Industry-Wide Challenge

Manufacturers across different verticals face similar hurdles in carbon tracking: fragmented data sources, complex supply chain emissions (Scope 3), limited internal technical and data resources, and evolving market expectations.

For this manufacturer, these common challenges were amplified by their multi-site operations, global reach and extensive supplier network. A scalable, user-friendly yet powerful data platform was critical to delivering reliable, comprehensive emissions insights without overwhelming internal teams.

Our Solution Approach

Operational Boundary Definition Working collaboratively, we helped the manufacturer clearly define which organisational segments and operational activities to measure, pinpointing exact carbon data boundaries for focused and accurate tracking.

Advanced Data Aggregation Recognising the diversity of their data streams, from utility bills and energy meters to supplier spreadsheets, we engineered a solution allowing high-volume data import without ERP disruption. This aggregation formed a single source of truth, vital for consistent analysis.

Tailored Supplier Data Integration For manufacturing supply chains where partners vary in sophistication, we designed intuitive data submission tools and simplified templates. This maximised supplier participation and significantly enhanced the quality and coverage of Scope 3 emissions data.

AI-Powered Emissions Mapping Our proprietary AI system automated the complex task of mapping raw data to specific emission sources, eliminating silos and offering real-time insights into emissions intensity and hotspots across the value chain.

Practical User Enablement We designed guided workflows complemented by hands-on training, ensuring staff could confidently handle carbon data tasks without requiring specialist technical skills.

Overcoming Implementation Challenges

Transitioning to digital carbon tracking involved process and technical shifts. Our phased rollout and dedicated support helped the manufacturer overcome initial hurdles related to data consistency, team adoption, and supplier engagement. This collaborative approach minimised disruption and accelerated value realisation.

Results Achieved

Comprehensive Organisational Carbon Footprint The manufacturer now possesses a verifiable, transparent carbon footprint baseline covering direct and indirect emissions across sites and suppliers.

Streamlined Workflows and Faster Reporting Automation reduced manual effort significantly, enhancing data accuracy and accelerating stakeholder reporting cycles.

Insightful Emission Hotspot Identification Advanced analytics highlighted key emissions areas, enabling targeted operational changes and efficiency gains.

Enhanced Internal Capability User-friendly interfaces and tailored training empowered team members, reducing external dependency and embedding sustainability expertise internally.

Market and Compliance Readiness With robust data and processes, the manufacturer is prepared to meet evolving regulations and increasing customer and stakeholder demands with confidence.

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Lessons for Supporting Manufacturers and Complex Supply Chains

This project reaffirmed that tailored, scalable carbon emissions management platforms paired with expert guidance can transform plastics manufacturers' approach to sustainability. Key insights include:

• Simple, flexible data input methods encourage supplier engagement even in less mature supply chains.
• Early and clear boundary setting streamlines measurement and avoids unnecessary data overload.
• AI-driven automated data mapping is essential to handle data complexity without overwhelming resources.
• Hands-on training and user-friendly design are critical for enabling diverse teams to become self-sufficient.

"Mavarick helped us see our data in a completely new light. Their team understood our business, listened to our goals, and delivered solutions that truly worked on the ground. Thanks to their expertise and practical approach, we now have both the insight and confidence to lead on carbon emissions and decarbonisation management and deliver even greater value for our customers." — Global Sustainability Manager

"Collaborating with this manufacturer highlighted that thoughtful technology adoption and partnership are key drivers for sustainable transformation in the plastics manufacturing sector. Their clear leadership and ambition made implementation purposeful and rewarding," says Koen Jasper, Mavarick Customer Lead.

Conclusion

Mavarick's partnership with this international plastics manufacturer offers a replicable model for how other manufacturers can meet rising carbon transparency demands with confidence. Through intelligent data management, AI-powered insights, and focused enablement, manufacturers can unlock sustainability leadership and strengthen their competitive edge in a climate-conscious market.

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