Thermal spray processes have increasingly become a common application in surface coating in the aerospace, automotive, and manufacturing industries. However, their energy consumption is typically high, increasing operating costs with considerable severe environmental drawbacks. This paper discusses strategies for improving the energy efficiency of various techniques of thermal spraying, namely plasma spraying, HVOF, and cold spraying. Optimization of process parameters, enhanced efficiency in convective heat transfer, and reduced energy losses are just some of the major solutions. Another area that the study has explored includes avenues related to advanced automation, material selection, and monitoring systems for minimizing energy consumption with no compromise on the quality of the coating. Case studies and experimental results indicate how these measures may eventually work toward energy savings, thus making thermal spray operations more sustainable and economically viable. This study provides a holistic framework for industries that would like to lower their carbon footprint while continuing to perform competitively through effective thermal spray practices.