China enters new era of ‘Dark Factories’ with no lights, no workers
China is on the cusp of a manufacturing revolution with the emergence of “dark factories,” fully automated facilities that operate without human workers or traditional lighting. Powered by artificial intelligence (AI), robotics, and advanced sensors, these plants represent the next step in the nation’s aggressive push toward industrial automation, positioning China as a global leader in technological innovation.
A “dark factory” is a production site where machines handle every task—assembly, inspection, and logistics—eliminating the need for human presence. Without workers, there’s no need for lighting, heating, or breaks, reducing energy costs and boosting efficiency. While fully operational dark factories are still rare globally, China’s rapid adoption of automation suggests they are becoming a reality. The International Federation of Robotics (IFR) reported that China installed 290,367 industrial robots in 2022, accounting for 52% of the world’s total, outpacing the U.S. and Japan combined.
This transformation is driven by the “Made in China 2025” initiative, launched in 2015 to make China a high-tech manufacturing powerhouse. The strategy emphasizes robotics, AI, and smart factories, with the government investing heavily in subsidies and infrastructure. By 2023, China’s robot density—robots per 10,000 manufacturing workers—reached 392, surpassing the global average of 141, according to IFR data. Companies like Foxconn and BYD are at the forefront, with Foxconn replacing 60,000 workers with robots in a Kunshan factory in 2016 and planning to automate 30% of its operations by 2025, as stated by Chairman Terry Gou in 2021. BYD uses robotic systems for EV battery and chassis assembly in plants like those in Shenzhen and Xi’an, further advancing toward workerless production.
Recent reports suggest that some Chinese factories are piloting “lights-out” operations, where precision manufacturing occurs in near-darkness using infrared sensors, LIDAR, and machine vision, eliminating the need for traditional lighting. The International Energy Agency (IEA) estimates that such automation can lower industrial energy use by 15-20% by removing human-centric infrastructure needs. China’s National Bureau of Statistics reported a 1.7% drop in industrial energy consumption in 2022, partly due to these automation gains, aligning with the country’s 2060 carbon neutrality goal.
Rise of dark factories raises significant challenges. Manufacturing employs over 100 million people in China, per World Bank data, and automation threatens widespread job losses. Oxford Economics projected in 2017 that 12 million Chinese manufacturing jobs could be lost to robots by 2030. A 2023 strike in Guangdong, reported by China Labour Bulletin, highlighted worker fears of robotic replacements, underscoring potential social unrest if retraining programs lag.
Globally, China’s progress intensifies competition. The U.S., with a robot density of 274 in 2022, and Germany, at 415, are accelerating their automation efforts, but China’s state-backed investment—Bloomberg reported $1.4 billion in robotics R&D in 2023—gives it an edge. The IEA notes that industrial automation could reduce CO2 emissions by 10% in heavy industries, though the environmental cost of producing robots remains a concern.
As of March 2025, dark factories in China are likely operating in pilot phases, particularly in high-tech sectors like electronics and electric vehicles. These facilities, running 24/7 with precision machines and no human workers, mark a shift toward a future where production occurs in near-darkness, driven by AI and robotics. Whether this heralds a new era of efficiency or amplifies social and environmental challenges will depend on China’s ability to balance innovation with adaptation.
Download Our Free Magazine
Get Industry Insights, Trends & Latest Innovations in the Textile & Apparel Industry
