Energy efficiency solutions at MachineBuilding.South

International energy efficiency standards have been steadily developing in recent years, most recently moving from IE4 to IE5 as the benchmark for efficiency. Forward-thinking motor manufacturers however, looking to future: Each successive jump in the standards has reduced energy losses by about 30% compared with the previous benchmark, so a number of motor makers have applied that thinking to the predicted IE6 standard, with a 20% reduction in losses compared to IE5.

As an example, Lenze (Stand 99) has recently introduced the m550 IE6 3-phase AC motor, covering the power range 0.25-7.5kW. And when combined with the i650 motec inverter, the result is a decentralised drive package that offers a powerful and energy-efficient solution for demanding applications.

The i650 motec impresses with its integrated Logic PLC and a positioning function that enables independent motion control without a higher-level controller. This makes the system suitable for various applications such as conveyor drives, winding drives and pump applications.

ABB (Stand 64) is accelerating industrial energy efficiency with its expanded range of

IE6 Hyper-Efficiency synchronous reluctance (SynRM) motors. This magnet-free technology brings next level efficiency and sustainability to even more industrial applications.

Designed with sustainability at the core, the IE6 SynRM contains no permanent magnets or rare earth metals, is 98% recyclable, and forms part of the ABB EcoSolutions portfolio with fully verified Environmental Product Declarations (ISO 14025 Type III). The SynRM motors match the size of stand IE4 induction motors, making them a simple drop-in replacement for fans, pumps, compressors and other applications. Paired with an ABB variable speed drive, they reinforce the company's commitment to breakthrough energy efficiency, reduced operating costs and helping industries accelerate their decarbonisation journey.

Another company anticipating the IE6 classification is WEG(Stand 54), whose W23 Sync+ Ultra motor integrates permanent magnet (PM) and magnetic reluctance technologies to achieve this high level of efficiency. That product has been an established motor since 2024, but the company is now looking even further ahead to anticipate what an IE9 standard might look like. An IE9 motor would reduce losses by 80% compared with an IE9 motor, achieving an efficiency of 99%. WEG is not quite there yet, but it does have a prototype which has achieved an impressive 98.6% efficiency at 500kW, with this result validated through extensive validation and testing by dynamometer.

For end users and machine builders alike, the benefits of adopting high efficiency motors are clear. ABB asserts that, compared with an IE4 motor, and IE6 motor will deliver savings of some 2,560 per year on energy costs. That would represent a payback of just 8 months.

And yet it is reckoned that half of the motors currently in use in industry are over 10 years old, representing the IE2 standard.

A more efficient motor reduces energy consumption, which directly translates into lower operational costs over time. Additionally, says WEG, highly efficient motors tend to have longer lifespans and require less maintenance, further reducing costs. From an environmental standpoint, the advantages against sustainability efforts are obvious.