Many maintenance staff work – understandably – according to the motto: “What works, won’t be touched.” Although this philosophy is justified in terms of smooth production, in the long term it forgoes considerable savings potential – because it is not seen.
A replacement with a modern IE4 or IE5 motor usually pays for itself after just one to four years through savings in power consumption across all standard outputs. For example, an old 37kW motor as shown in the photo can be assumed to have an efficiency of 91.2% (IE1). Modern IE4 motors, on the other hand, have an efficiency of 94.5%. With just 2500 operating hours per year, the immediate purchase of a new IE4 motor will pay for itself in just three years.
Nevertheless, only a few of these super-premium efficient drives are installed in production facilities, as there is no incentive to proactively replace them. The reason: maintenance staff are measured by smooth operation and their expenses, not by the strategic optimization of energy consumption.
Why energy-saving measures must be supported by the CEO
It is therefore a management task to create clear guidelines. Responsibility can only be lifted from the shoulders of the maintenance department by explicit instructions from the very top. The goal must be: If a motor fails, neighboring motors are also checked. And if a gain in energy efficiency is expected, they will be replaced at the same time. After all, if the system is already in place, the opportunity should be taken to push ahead with modernizations step by step.
This also applies to new projects. Anyone who saves today by limiting themselves to the minimum energy efficiency standards will pay twice as much tomorrow with every electricity bill. Instead of saving on efficiency, the choice of brand should be approved – always while maintaining the minimum technical requirements and checking the reliability of the supplier. Modern, highly efficient electric motors are now available from many qualified manufacturers; MOLL-MOTOR’s own brand covers the industry standard range, while MOLL-MOTOR also acts as a distributor for several other manufacturers.
The Austrian Energy Agency recently published figures showing that electric motors account for around 70% of electricity consumption in industry. At the same time, energy savings of up to 20% are possible with replacement projects, and even projects with savings of 3% or 4% quickly pay off, as energy consumption accounts for more than 90% of the life cycle costs of a motor. MOLL-MOTOR offers a broad portfolio of IE3, IE4 and even IE5 motors as well as sound advice and future-oriented concepts for sustainable modernization.
Take the right steps now
A clearly communicated top-down strategy for increasing the efficiency of drive systems is the key to success. The technical feasibility is given, the economic sense is proven. The final step to success is internal company commitment. MOLL-MOTOR supports companies in implementing this strategy and making the changeover efficient.
