Hydrogen Finds a Shortcut Onto the Factory Floor

Factories are using hydrogen retrofits to cut fuel use and emissions years before Europe’s hydrogen pipelines are ready

17 Dec 2025

A growing number of European manufacturers are cutting emissions by adding hydrogen to existing industrial equipment, rather than waiting for large-scale hydrogen pipelines and networks to be built.

The approach, still at an early stage, involves producing hydrogen on site and blending it into natural gas systems already used for industrial heat. Companies say the method can reduce fuel consumption and emissions without replacing core machinery or interrupting production.

At a Volkswagen manufacturing site in Poznań, hydrogen is being introduced into an existing natural gas burner used for heating. The hydrogen is generated on site using electricity and water, then mixed with gas before combustion. Volkswagen has said the system improves efficiency while lowering carbon emissions, without requiring major changes to plant operations.

Industrial heat is one of the most difficult parts of manufacturing to decarbonise. High-temperature processes often cannot be easily electrified, and switching fuels can involve high capital costs. By modifying existing systems, manufacturers are able to make incremental but immediate reductions in emissions.

The technology used at the Poznań site was supplied by Hydrogenera, a company focused on retrofitting existing industrial infrastructure for hydrogen use. According to performance data shared by the company, fuel consumption can fall by up to 30 per cent, depending on operating conditions. Lower fuel use can also reduce energy costs, particularly where hydrogen is produced using relatively cheap electricity.

Analysts say such projects complement Europe’s longer-term plans to build hydrogen hubs and cross-border pipelines. While the EU has set out ambitious targets for hydrogen production and transport, much of the infrastructure is not expected to be operational until the 2030s. Smaller, decentralised projects allow manufacturers to act sooner.

“These early deployments help create local demand for hydrogen,” said one industry analyst, adding that this could support future investment in storage, transport and distribution networks.

There are limits to the model. The environmental benefit depends on the price and carbon intensity of electricity used to produce hydrogen. Regulators are also tightening rules on how emissions savings are calculated and verified, particularly for projects linked to green finance.

Even so, interest is increasing. Hydrogen retrofits are moving beyond pilot projects and into regular industrial use. For manufacturers facing pressure to cut emissions quickly, they offer a practical option while Europe’s hydrogen infrastructure slowly takes shape.