This work presents a novel approach to sustainable manufacturing by integrating intelligent control with real-time thermal monitoring and modelling to optimize process parameters for improved productivity, surface integrity (SI), product lifecycle, minimized costs and reduced environmental impact. Manufacturing processes generate heat signatures that reflect underlying process mechanics and directly influence SI, which governs product durability and lifecycle emissions. A smart tool embedded with a Transverse Heat Flux Sensor (THFS) was developed to capture high-speed thermal data, including direct heat flux measurements, during machining. A key experimental finding is the correlation between normalized cutting force and normalized heat flux (R² = 0.564), validating Heatmetry as a reliable proxy for process load and energy transfer. The system enables predictive control of process parameters to minimize cumulative energy demand (CED) and CO₂ emissions while maximizing product quality and longevity. The outcomes support the development of digital twins and intelligent control systems for zero-emission manufacturing through real time data acquisition.