How a sustainability mindset is shaping the future of construction and agriculture—starting from the factory floor.
Merlo is known across the world for its innovative handling solutions—but the company’s commitment to sustainability runs deeper than the green paint on its machines. From cutting-edge electric telehandlers to solar-powered facilities and circular waste systems, Merlo is driving a comprehensive, group-wide shift toward cleaner, smarter operations.
And this transformation isn’t just happening in Italy. The UK team is taking the same ambitious steps, proving that sustainability is not a one-off project—it’s a culture.
Sustainability at the Source: Inside the Italian Factory
At Merlo Group’s headquarters near Cuneo, Piedmont, sustainability begins long before a machine leaves the production line.
The site is powered in part by an extensive photovoltaic array, which in 2024 alone produced 1,150 MWh of clean energy—avoiding approximately 750 tonnes of CO₂ emissions, the equivalent of planting over 4,500 trees. The goal? To reach energy parity—generating as much electricity as the site consumes.
But green power is just the start.
Circular Thinking: Waste Reduction and Material Recovery
Merlo has taken major steps to minimise its environmental impact through smart waste and resource strategies:
- Over 30 compacting presses manage the recycling of cardboard and plastic packaging.
- Metal filings and scrap offcuts from sheets are systematically collected for reprocessing.
- Employees are encouraged to shut down IT equipment when not in use—small actions that, collectively, lead to substantial energy savings.
- Sensor-activated taps minimise waste water in restrooms, while digital transformation initiatives have drastically cut printed paper usage by transitioning communication and records to digital platforms.
These might sound like operational details—but they reflect a much larger ambition: to build machines sustainably, from the inside out.
Efficiency Where It Matters
Energy-saving measures continue across the facility:
- A site-wide transition to LED lighting is underway, with systems that use up to 90% less energy than traditional fixtures.
- Dusk sensors and automated heating systems regulate lighting and temperature in key departments, using smart home tech to avoid waste.
- New production buildings are being built with enhanced insulation, ensuring thermal efficiency and reducing heating and cooling demands.
- Upgraded production equipment and streamlined logistics reduce internal fuel consumption and optimise operations.
Every innovation within the factory is designed to do more with less—less energy, less waste, and fewer emissions.
Generation Zero: Sustainable Machines for a Modern World
Merlo’s environmental commitment doesn’t end at the factory gates. It’s carried forward into the machines themselves.
The eWorker, Merlo’s fully electric telehandler, is a standout. Zero-emission, near-silent, and packed with eco-innovation—from regenerative braking and auto start-stop to a recyclable battery system—it’s proof that green performance doesn’t mean compromise.
Also in the spotlight are the ROTO Plug & Play Hybrid, delivering full-size performance with significantly reduced emissions, and the eCINGO, a compact, electric tracked carrier built for clean operation in confined or indoor environments.
But these are just the beginning. Several other models in the Generation Zero line are currently in concept development or pre-production, set to expand Merlo’s sustainable range even further. As these machines transition from prototype to production, they will reinforce the group’s long-term commitment to offering a complete portfolio of low- and zero-emission handling solutions.
Together, they signal that sustainable handling isn’t a distant goal—it’s an evolving reality. And Merlo is leading the way
Merlo UK: Following in Sustainable Footsteps
In the UK, the green ethos is equally strong. Merlo UK has embraced solar energy at its base in Ringwood, Hampshire, where rooftop panels now help power operations and employee vehicles. Any unused energy is fed back into the grid—closing the loop on responsible energy use.
Where appropriate, the car policy is for hybrid vehicles, while recyclable packaging has replacing traditional materials in logistics and parts distribution.
In 2023, Merlo also began a gradual transition to more sustainable shipping methods for machines bound for the UK. Where possible, units are transported across Europe via electric freight trains, with sea crossings handled by hybrid LNG/electric vessels—further reducing the carbon footprint of every machine before it even reaches UK soil.
These are not just token efforts—they’re part of a long-term commitment to embed sustainability into every corner of the business.
Sustainability is in Our DNA
Whether it’s a technician shutting down their workstation to save power, a manager reviewing LED retrofitting plans, or an engineer fine-tuning a new-generation electric telehandler, Merlo’s teams—across Italy and the Merlo group —are united by a shared goal: to create a cleaner, smarter, more sustainable future.
As Shaun Groom, Managing Director of Merlo UK, puts it:
“We all have a responsibility to future generations. Sustainability is about more than the machines we deliver—it's about how we build them, how we power them, and how we run our business day to day.”
It’s not just the machines that are evolving. It’s the mindset.
Merlo’s Sustainability in Numbers (box)
- 1,150 MWh of solar energy produced (2024)
- 750 tonnes of CO₂ saved—equal to planting 4,500+ trees
- Over 30 compacting presses across the factory
- 90% energy savings from LED lighting rollout
- 100% electric eWorker telehandler in production
