JSW Steel’s Salem plant has committed to achieving Net Zero emissions by 2050, with a specific focus on reducing greenhouse gas emissions from its coal-based steam generation systems. Biomass, including briquettes, spent coffee grounds, wood chips, rice husk, and cattle dung logs, has been identified as a key component in reducing these emissions, particularly through its incorporation as a supplementary fuel in coal-fired boilers. This paper presents a comprehensive analysis of the challenges and solutions related to biomass fuel preparation, including briquette sizing, feed optimization, and contamination control. We propose an innovative action plan aimed at enhancing biomass fuel efficiency through optimized fuel size control, expanding biomass supply, and fostering deeper collaboration with suppliers. This action plan has resulted in a significant reduction in CO₂ emissions, with approximately 8,000 tons of CO₂ reduced annually a 5-10% improvement in boiler efficiency, and substantial cost savings due to reduced coal consumption through biomass blending. The novelty of this work lies in its comprehensive approach to biomass utilization, addressing challenges across the entire process from fuel preparation to combustion, and its focus on a real-world industrial setting using an AFBC boiler. In addition, we assess the plant’s current biomass fuel mix and compare it to India’s national strategies for sustainable energy utilization. The technical measures discussed herein for improving biomass feed systems contribute to improved boiler efficiency, higher fuel blending ratios, and substantial reductions in greenhouse gas emissions. these findings support broader sustainability goals and offer valuable insights for industries in India aiming to reduce their carbon footprints.