Carbon Footprint Accounting and Emission Hotspot Identification in an Industrial Plastic Injection Molding Process

Climate change is one of the most pressing global environmental challenges, driven by the accumulation of greenhouse gases in the atmosphere. Industrial processes, particularly plastic injection molding, are major contributors due to their high energy demand, raw material use, and waste generation. This study quantifies the carbon footprint of plastic injection molding operations and identifies emission hotspots to support alignment with sustainability objectives. A greenhouse gas inventory was developed for the production processes of Petka Mold Industry in Adana, Türkiye, covering 1 January–31 December 2023. The assessment followed the ISO 14064-1:2019 standard and included emissions from direct fuel consumption, purchased electricity, refrigerant leaks, company vehicles, employee commuting, business travel, purchased goods, and waste transportation. Carbon dioxide, methane, and nitrous oxide were calculated in carbon dioxide equivalent units. This research represents the first comprehensive carbon footprint study in the plastic mold sector integrating all categories (Categories 1–6). In addition, uncertainty and materiality analyses were applied to ensure robustness and transparency, an approach rarely adopted in similar industrial contexts. While most previous studies are limited to Categories 1–3, this work expands the boundaries to all categories, offering a pioneering model for industrial applications. The total corporate GHG emissions for 2023 were calculated as 3922.75 metric tons of CO2e. Among the categories, purchased raw materials and end-of-life product stages were the most significant contributors, whereas transport and auxiliary services had smaller shares. The results provide a reliable baseline for developing action plans and pursuing emission reduction targets. By combining full category coverage with rigorous assessment tools, this study contributes methodological novelty to corporate carbon accounting and establishes a foundation for future progress toward carbon neutrality.