In today’s increasingly tech-driven world, the demand for reliable and efficient power supplies and chargers is at an all-time high. This is especially true for USB Power Delivery (PD) chargers, essential for powering a wide range of devices from smartphones to laptops, and non-USB power adapters for a whole host of IoT devices, gadgets and toys. But it’s not all about the actual product itself; the manufacturing, shipping and other factors play a big part in the environmental impact of these products.
In 2025, around 900 million PD chargers were shipped worldwide, with 96.7 million being the newer style GaN chargers. Shipments of these products are forecast to increase by 15% year on year to 2030, with GaN charger growth forecast to be 20% year on year for the same period. Non-USB power adapters shipped in the same period were around 350 million, with growth expected to be around 5% annually to 2030.
Six levers that shape sustainable supply
When planning the supply of adapter power supplies and chargers, six core levers determine both environmental impact and business performance: design, manufacturing practices, energy sources, material sourcing, vertical manufacturing, and sustainable shipping.
1. Design
In designing power supplies, there are many factors to be considered for both the user and the environment.
From a user perspective, the product must be safe and efficient, reliable and aesthetically pleasing.
For the environment, the power supply should use components and materials that meet the requirements of RoHS, California Proposition 65, WEEE, REACH, Energy Star and other Green Certification programmes adopted across the world. This reduces compliance risk, lowers chances of re‑designs or recalls, and protects your brand in regulated markets. There is also a move to adopt more eco-friendly materials that prioritise recycling and to have biodegradable options to minimise environmental impact. Production design is another important consideration to ensure that the manufacturing process is efficient and utilises the minimum amount of resources whilst not affecting quality.
The implementation of design strategies that prioritise functionality and environmental responsibility can significantly reduce their carbon footprint.
2. Manufacturing Practices
The manufacturing process of adapter power supplies is critical, as it directly impacts product quality, performance and sustainability.
For product quality, the factory must have a progressive quality management system that complies with ISO9001. For environmental management, the quality system must be backed up with accreditation to a standard such as ISO14000.
For you, this means more consistent quality, fewer field failures, and smoother customer audits.
Properly managed quality and environmental management systems build the factory’s reputation but also ensure compliance with regulatory requirements.
3. Energy Sources
Energy usage within a manufacturing facility is significant, and considering the source of energy is a major consideration with respect to the environment and associated CO2 emissions.
Sourcing energy from renewable sources is another vital consideration in supplying power supplies and chargers. Manufacturers are increasingly recognising the importance of sustainability in their operations, but in most cases, they are unable to select how their energy is generated. If available, the selection of renewable energy sources such as solar or wind can drastically reduce the carbon footprint of a manufacturing facility.
For customers, this translates into a lower embedded carbon footprint per unit and clearer evidence to support sustainability reporting.
4. Material Sources
The materials used in the construction of power supplies and where they come from have a lasting impact on the environment.
It is crucial to source locally, where possible, to minimise the impact of shipping. All carriage methods should utilise the most environmentally friendly methods, including product density control.
Packaging materials, boxes, pallets, etc., should be reusable, made from recycled materials, and not contain any harmful substances; any waste must be kept to a minimum.
In sourcing, manufacturers must ensure that vendors adhere to the same environmental standards and accreditations as themselves. This not only cuts emissions from transport and packaging waste but also reduces the risk of supply disruptions from non‑compliant vendors.
5. Advantages of Vertical Manufacturing
Vertical manufacturing, where a company oversees and controls the entire production process from design to assembly, offers significant environmental benefits.
This approach not only allows for greater control over quality and consistency but also enhances agility in response to market demands.
Companies can optimise production efficiency, reduce lead times, and diminish costs associated with outsourcing components. Furthermore, vertical integration can facilitate sustainability efforts by allowing the implementation of eco-friendly practices throughout the supply chain, ensuring that every step contributes to a more sustainable outcome.
For buyers, this means faster time to market, more predictable costs, and fewer emissions from moving semi‑finished goods between multiple sites.
6. Sustainable Shipping
Shipping is a major contributor to the environmental impact of the end product, and it is crucial that, like the design and manufacturing process, this is managed proactively.
Sustainable shipping practices are crucial to minimising the environmental impact of transporting products. By optimising logistics and investing in eco-friendly packaging materials, companies can reduce their carbon footprint during the distribution of their products.
Sustainable shipping practices include ensuring that shipping partners meet and are accredited to the latest industry guidelines and legislation for the reduction of harmful emissions. Where possible, and as costs allow, partners that exceed the requirements are preferable. Consolidating shipments to reduce transportation emissions and implementing efficient route planning to further lower environmental impact must also be considered.
How does Conexa Tech manage the Sustainability of Supply?
Conexa Tech takes its responsibility to the environment seriously and works with its partners to deliver best-in-class environmental practices in reference to the supply of adapter power supplies and PD chargers.
Design: Factory quality management (ISO 9001), environmental management (ISO 14000) and hazardous substance process management (IEQ QC 08000) systems are part of the design process from the initial concept. This ensures that the environmental impact of all news designs is considered up front and is not an afterthought.
Manufacturing: The factory utilises vertical manufacturing techniques to minimise environmental impact. This includes manufacturing its own PCBs, cables and moulding power supply plastic cases. The shipping of raw materials rather than finished products is more efficient and significantly impacts emissions. This vertical model also helps shorten lead times and gives better control over cost and quality.
Energy Sources: The factory is focused on reducing CO2 emissions as a consequence of manufacturing processes. A key ability of the factory to reduce is provided by generation of 40% of the electricity it uses through its own on-site solar array. A system that will be increased to 60% in the future. To our knowledge, this places the factory among the very few power supply facilities globally with this level of on‑site solar generation.
Shipping: As a major factor in CO2 emissions, shipping methods are considered carefully. We work with a shipping partner that meets the highest standards in CO2 reduction through both meeting legislation and having a dedicated team to drive emissions reductions. This includes replacing their vehicle fleet with zero-emission electric vans and lorries. We aim not to use air freight and consistently research new shipping methods, such as train, to ensure the minimum level of emissions.
For example, a global IoT customer consolidating production into our vertically integrated, solar‑powered facility reduced estimated logistics‑related emissions while maintaining on‑time delivery. By optimising packaging density and shifting from air to sea and rail where feasible, they achieved a double‑digit percentage reduction in transport emissions per unit without increasing total landed cost.
Conclusion
As the demand for adapter power supplies, including PD chargers, continues to rise, manufacturers must consider the broader implications of their supply chain practices. Focusing on sustainable manufacturing, energy sourcing, material selection, the benefits of vertical manufacturing, and eco-friendly shipping can lead not only to enhanced product performance but also to a significant reduction in environmental impact. By prioritising these core considerations, companies not only meet the needs of the present but also contribute to a more sustainable future for generations to come.
If sustainability, quality and reliability are priorities for your adapters and PD chargers, contact Conexa Tech to review your current power supply portfolio and identify practical ways to cut emissions while protecting cost, performance and supply security.
