FEATURE
DRIVES, CONTROLS & MOTORS
EFFICIENCY FIRST: THE FAST LAN With around 45%
of global electricity consumption coming
from industrial motors, improving their
efficiency is essential to cutting the world’s energy use – and, the technology to do this is already available.
Ivor Vidjen, global head of strategy & business development ABB IEC Low Voltage Motors, explains
another powerful solution that doesn’t get nearly enough attention: energy efficiency. At ABB, we actively support the growth of
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renewable energy – but it can’t be our only answer. As we work to expand clean energy supplies around the world, one crucial message cannot get lost in translation: it’s not just about generating more energy to meet demand, it’s about using less of it to begin with. An unused megawatt is better than a newly
generated megawatt. Energy never consumed is indeed the cleanest, cheapest, energy available. No wonder the International Energy Agency labels energy efficiency as the ‘First Fuel’ in our journey towards Net Zero.
Ivor Vidjen
hen most people think about the energy transition, they picture wind turbines and solar panels. But there’s
IMPROVING MOTOR EFFICIENCY Electric motors are embedded in nearly every aspect of modern industry, powering critical systems like pumps, fans, compressors, and conveyor belts. With approximately 45% of global electricity consumption coming from industrial motors, improving their efficiency is
“The IEC efficiency
standards lay out a series of recognised
motor efficiency levels, which progressively
show 20% fewer energy losses with each level”
one of the most potent strategies for cutting the world’s energy use. And the technology to do it is available today. The IEC (International Electrotechnical Commission) efficiency standards lay out a series of recognised motor efficiency levels, which progressively show 20% fewer energy losses with each level, ranging from IE1 to IE5 (~96%
54 DESIGN SOLUTIONS JUNE 2025
efficient). These figures are already being surpassed. The unofficial but Hyper-Efficient IE6 synchronous reluctance (SynRM) motor design, for example, transcends IE5 by providing a further 20% reduction in energy losses. Pairing IE6 motors with Variable Speed
Drives (VSDs) further optimises motor performance by enabling them to operate at precisely the level of speed each application demands. Without a VSD, motors typically run at full speed regardless of actual demand, leading to significant energy waste, especially under low-load conditions. Despite undeniable efficiency benefits, fewer than 25% of motors currently used globally are equipped with VSDs – it’s a huge missed opportunity. By integrating their motors with VSD
technology, organisations can significantly lower energy usage, cut operational expenses, and make substantial progress toward greater sustainability. Proactive energy efficiency initiatives – particularly within industry – can deliver immediate, measurable benefits. Reducing overall demand not only accelerates the transition to clean energy, but lowers costs in the process.
SMART INVESTMENTS IN ACTION A prime example is ABB’s collaboration with Aurubis, the leading copper producer in Europe. At its plant in Pirdop, Bulgaria, the company replaced 460 older motors with ABB IE4 and IE5
The SynRM motor design transcends IE5 by providing a further 20% reduction in energy losses
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