Are you interested in reducing your energy costs?
Improving business operations with smart motor and inverter solutions – that’s simple.
It’s what saves money, increases production, and reduces energy consumption. The best part is, it can pay for itself in no time.
So, what are we going to cover?
- The importance of motors in industrial applications.
- The actual cost of outdated technologies.
- The way smart inverters revolutionize processes and tasks.
- Calculate how much money you can save.
Why Motors Matter To Your Bottom Line
First of all, we would like to talk about something that is important to every business.
Industrial electric motors are those that consume the largest share of the energy. They are used in all areas. This is the main power source for almost all production processes.
And it’s those processes that are working overtime. Electric motors account for 45% of global electricity usage. In the most energy-intensive sectors, motors are the central power consumers. These are mining, metallurgy, production of building materials, chemical, food, and woodworking industries.
They are running 24 hours a day, around the clock, often with high load, and therefore consuming significant amounts of electrical energy.
For example,
if your company is still using basic-efficiency motors that are over 10 years old, you can count on the fact that you are losing money. New electric motors and smart inverters can significantly reduce energy consumption.
Increasing the energy efficiency of motors and using smart inverters for your business are not only an environmentally friendly solution. It is also necessary to stay in the modern world.
The True Cost Of Old Technology
There’s one little fact you might not know…
Motor’s total cost of ownership is 97% due to the electrical energy consumption. The initial cost of the motor is just 1% of the total expense incurred over the motor’s lifespan.
Therefore, when you are calculating if it is worth upgrading, do not look at the first cost. The investment will be quickly returned by the potential electrical energy savings.
Facilities that switch from conventional to energy-efficient IE3 and IE4 class motors can achieve energy savings of 20-30% on motor lifecycle energy consumption. If a facility operates several or even hundreds of motors, then the whole system of motors will generate significant cost savings.
But there’s more to it…
Standard motors produce additional heat, which affects a more frequent maintenance. Also, conventional motors have a smaller service life, are less resistant to voltage jumps, and have a negative impact on the stability of the electrical network.
Smart Inverters Change Everything
Variable speed drives (VSDs) – also known as inverters – can be a complete game changer.
The reason for it is that:
Old-fashioned motors are single-speed. They rotate at the same speed, regardless of how much load they have to process at a particular moment.
Smart inverters will adjust the motor operation. The number of revolutions, the torque, everything will be adjusted just in time and will be exactly what the process needs. This will typically reduce energy consumption by at least 25%.
All of these cases: pumps that do not have to work at full capacity all the time; fans that can turn down when the need for cooling is reduced, conveyors, which can change their speed depending on the flow of production, etc. A fixed-speed motor will waste energy.
Inverters will get rid of that waste.
Also, there are more benefits of the inverter to your business other than just energy efficiency:
- Reduction of mechanical stress on equipment;
- Reduction of maintenance costs;
- Improved process control;
- Longer equipment lifespan;
- Reduced strain from start-ups and shut-downs.
High efficiency motors and inverters form a single system. This system will be much smarter and more responsive, which will significantly reduce its cost.
Calculating The Amount Of Money You Can Save
Now it is time to talk about the specific benefits to your business.
Companies in developing countries that have started to use energy-efficient motors can reduce their energy costs by up to 40%. Developed countries are not lagging behind.
Let’s take an example:
A production facility that uses older motors with high utilization. In this case, the cost of energy is one of the largest operational costs. By replacing standard motors with IE3 or IE4 class motors and install inverters, this facility will have a payback period of less than seven months.
After that, only profit, for years.
If you add the reduction in maintenance, which, by the way, also works. The motor has less heat, less thermal stress on its components. It also means fewer breakdowns, less downtime, fewer repair costs.
Smart Businesses: The Choice Is Yours
The energy efficient motor market is estimated to reach USD 91.9 billion by 2033 from USD 44.2 billion in 2023.
Why? Because smart companies that care about efficiency, saving money and equipment, and have the responsibility in the market, are aware that motors and inverters are not just maintenance materials.
Motors and inverters, in addition to being an important part of your daily operation, also directly affect your company’s profitability.
Governments are also concerned about energy efficiency. The European Union’s Ecodesign Directive, the US Department of Energy, and similar authorities and regulations are currently regulating markets and setting efficiency standards that all products must meet.
It is not necessary to wait for the state to force. This is just an extra incentive.
Companies that make a decision to improve their operations using smart motors and inverter solutions are gaining an advantage through lower operating costs. This will help you in sustainability reporting, which is of interest to your clients and investors in order to achieve your CSR (Corporate Social Responsibility) targets.
Where Do You Start?
If you have made a decision to improve your operations using Smart Motor & Inverter Solutions, then we advise you to begin.
Audit your existing motor installations. Pay attention to motors that run with a high level of load, and/or the oldest ones. They are the top priority for upgrades.
Seek suppliers who are aware of industrial applications, and can advise you on the efficiency class of motors that is best for your use case. Not all motors need to be IE4, but it is important to know which do.
Consider doing a pilot project. Replace some motors in one line of production or in one section of the facility. Analyze the results. You will clearly see the energy savings. It will be very easy to make the decision to continue and introduce solutions across the entire production facility.
And, of course, do not forget about inverters. If it is not possible to immediately replace motors, even adding a VSD to existing motors will allow you to receive immediate energy savings.
The main thing is to start.
Final Thoughts
Improving business operations with smart motor and inverter solutions is not a difficult task.
It’s about making the right decisions that will reduce costs, increase reliability and allow you to keep up with the times.
The technology is reliable, the savings are tangible, and the payback period is quite small.
Every day you run motors that are outdated, inefficient, and poorly maintained, your business just loses money.
At the current time, when every business is fighting for its survival, this is an expense you can not afford to have.
The profit from your business will thank you!
