Motor control solutions: Driving efficiency and savings across industries

Australia’s path to Net Zero by 2050 underscores the critical importance of enhancing energy efficiency. However a recent global survey by ABB, which included over 2000 businesses, revealed that 50% listed cost as the biggest barrier to improving energy efficiency. What many of these businesses may not realise is that investing in efficient technologies not only contributes to net zero targeting but also yields substantial cost savings. The exciting prospect lies in the availability of energy-efficient technology today that maximises return on investment and minimises emissions. IPD is at the forefront of this transition, offering leading-edge technologies from ABB to facilitate the nationwide adoption of higher-efficiency motors. Through ABB’s suite of digitalised energy efficiency tools, businesses can align themselves closer to their sustainability goals whilst also reducing their operating costs. Here is what businesses need to know.

Electricity: the real cost

Electricity is typically an industrial facility’s greatest single operating expense. Electric motors, in turn, are generally the most energy-intensive components within a facility, with the Australian Bureau of Statistics measuring a 2% increase in energy usage in 2023. Therefore, the opportunity to reduce business operating costs through investment in energy-efficient technology will not only impact on the bottom line, but also the wider environment.

Ultra-premium efficiency with IE5 SynRM motors

ABB’s IE5 synchronous reluctance motors (SynRM) deliver an ultra-premium energy efficiency. The IE5 class is a new level of efficiency defined by the International Electrotechnical Commission (IEC), highlighting the SynRM motor as the new first choice to meet the growing global demand for improved energy efficiency.

The IE5 motor offers up to 40% lower energy losses, and significantly lower energy consumption and CO₂ emissions compared to commonly used IE3 motors. SynRM motors have a low environmental footprint because they are manufactured without using rare earth materials. Moreover, they have a low carbon footprint over their complete lifecycle, from production to recycling, with the best low-emission performance in their class.

Getting the most out of motors with variable speed drives

Operators can further improve their efficiency and energy savings by employing variable speed drives (VSDs) to control their motors, which can cut a motor’s energy consumption by 25% or more. A VSD works by controlling and optimising motor speed and torque to changing requirements, reducing energy wastage. This is compared to traditional motors, which run constantly and uneconomically at full speed, or require slowing down by mechanical controls, which can result in significant energy waste. Currently about 23% of motors in the world are equipped with VSDs, representing a significant opportunity to improve the energy efficiency of motors globally. When a VSD is paired with a modern, high-efficiency motor, such as the IE5 SynRM, the overall result is an even greater energy economy.

Lower energy use results in lower TCO

Although companies can be reluctant to upgrade to an IE5 SynRM-Drive package due to the upfront investment costs, this investment can be justified easily based on energy savings alone, often paying for the difference in as little as a year. Beyond that, the motor will continue to yield savings for its entire ten-plus-year lifespan. Looking at the total cost of ownership (TCO) makes this clear: approximately 97% of a SynRM motor’s TCO results from the electricity used to power it, with maintenance accounting for 1%, and the motor’s capital expenditure for just 2%. Moreover, when a standard IE3 induction motor is paired with a VSD, energy bills are reduced typically by up to 25%. In addition, employing the complete SynRM-Drive package can result in additional savings of around 3–4%. As well as improving energy efficiency, a SynRM-Drive package offers reliable performance, low maintenance costs, and easy retrofitting into existing installations, or incorporation into new projects and OEM designs.

Go green, save money

On the road toward net zero emissions, highly efficient motor and drive technology gives industry a head start. By making operations more energy-efficient, productive and profitable, decarbonisation becomes economically viable for business while at the same time benefiting the planet.

For more information, contact IPD on 1300 556 601 or visit here.