Architecting Net-Zero: An Integrated Framework Aligning Industry 5.0, Circular Systems, and Deep Decarbonization
Abstract
The global transition toward net-zero manufacturing is increasingly urgent as industrial sectors face mounting regulatory pressures and severe resource constraints. While isolated advances in digital optimization and renewable energy integration have been achieved, existing operational frameworks suffer from critical shortcomings. Predominantly, previous systems rely on siloed, fragmented methodologies that treat digitalization, circularity, and chemical decarbonization as separate operational tracks, leading to systemic inefficiencies. This review critically evaluates current green manufacturing pathways, systematically adhering to PRISMA guidelines to synthesize recent high-impact literature. The scope encompasses the expanded 10R circular framework, Industry 5.0, Environmental, Social, and Governance (ESG) mandates, and deep decarbonization technologies. A vital component of modern compliance is rigorous Scope 1, 2, and 3 Greenhouse Gas (GHG) accounting, which provides the mathematical foundation for tracking embedded carbon throughout the complex supply chain. Analysis indicates that while digital twins and Artificial Intelligence (AI) optimize immediate energy efficiency, long-term net-zero targets require capital-intensive structural pivots to technologies such as Hydrogen-based Direct Reduced Iron (H2DRI) and Carbon Capture, Utilization, and Storage (CCUS). To address the limitations of existing, fragmented models, this manuscript proposes a novel Integrated Framework for Green Manufacturing. By tightly coupling human-centric Industry 5.0 cyber-physical systems with advanced circular ecosystems and rigorous ESG validation, the framework offers a cohesive roadmap for industrial decarbonization. The unique contribution of this manuscript lies in mathematically and operationally bridging the gap between digital efficiency tools and structural chemical decarbonization, ensuring scalable, long-term planetary sustainability.