Boosting efficiency in manufacturing environments

New EU motor efficiency regulations signal opportunities for businesses.

According to The Times, 20 per cent of business owners expect the UK’s cost of living crisis to hit them harder than the COVID pandemic­­. The pressure is on all businesses, including manufacturers, to achieve greater cost-efficiency throughout their operations, well into the future. Here, Marek Lukaszczyk, European and Middle East marketing manager at motors and­­ drives specialist WEG, looks at how pending updates to Commission Regulation (EU) 2019/17 could help manufacturers improve motor efficiency, and reduce costs.

The UK’s cost of living crisis will give businesses, as well as households, much to contend with. One is rising energy costs. According to the UK Government, the cost of electricity within the manufacturing industry increased by 72 per cent during the last decade, and 280 per cent over the past 20 years. But, could what at first seem like challenges actually inspire manufacturers to improve their operations?

According to Laura Capper, Head of Manufacturing and Construction at NatWest Group, “During the pandemic, manufacturing businesses demonstrated extreme resiliency.” Capper adds that, “while the current inflationary environment creates even more pressures, energy and fuel price rises are a catalyst to consider energy efficient and sustainable alternatives to help manage business costs.”

One apparent challenge that might offer a saving grace for manufacturers are the pending updates to Commission Regulation (EU) 2019/17, set to be introduced by the European Union (EU) in July 2023. The new legislation could help manufacturing environments become more efficient while offering respite for manufacturers dealing with rising operational costs. Below, we’ll examine how.

New Ecodesign energy requirements (EU) 2019/1781

The pending updates to the European regulations for Ecodesign are the second stage of the legislation changes, following the stricter regulations that came into effect in July 2021, setting out new energy efficiency standards for motors and drives.

From July 2023, this now includes motors that produce between 75 and 200 Kilowatts (kW) of power, where a minimum International Efficiency Class 4 (IE4) will be standard. IE5 is currently the highest efficiency ranking for motors and is described as ultra-premium efficiency. IE4 refers to super-premium ratings, IE3 motors are noted as having premium efficiency, while IE2 is categorised as high efficiency and IE1 is for standard efficiency.

According to the updated regulations, hazardous area Ex eb increased safety motors (all poles) with a rated output between 0.12 kW and 1,000 kW must now reach the IE2 standard, as a minimum. This means that in settings where explosion protection is necessary such as in gas and oil centres or flour mills, motors should now hit higher efficiency ratings. The new rules will also demand that single-phase motors with 0.12 kW power output or above should now have an IE2 level of efficiency as a baseline.

The extra efficiency details from manufacturers, to be included with motors and drives from July 2023 onwards, can also help purchasers make better ꟷ and more sustainable ꟷ motor choices. The details must include efficiency data relating to the different performance settings and show efficiency changes across different loads, speeds and levels of torque.

Although the updated regulations will only apply to motors that are new off the production line, businesses can also upgrade their existing equipment and manufacturing processes to boost their overall energy efficiency.

Reduced maintenance  

For more efficient use of motors, WEG recommends installing soft starters on machines and motors that run intermittently.

Soft starters limit the load and torque in a power train by increasing the power incrementally, instead of starting the motor suddenly, at full voltage, which creates mechanical stress. A soft starter can reduce the energy in-rush needed to kick-start a motor by 60 per cent. This has been found to save operators large sums over the course of a decade. First, by reducing the initial energy expenditure needed to get the motor running and, second, by reducing wear and damage to the motor that leads to maintenance costs and likely production stoppages.

Another way in which manufacturers can achieve cost savings is through the use of a variable speed drive (VSD). A VSD is an electronic device with the functionality to calculate and adjust its speed based on the required demands. Put simply, VSDs are able to convert the relative input into a corresponding output.

The advantages of combining WEG VSD drives and motors were demonstrated at Manchester Central exhibition centre. When using a VSD to reduce the power of an electrical motor to 80 per cent of its capacity can reduce its overall energy consumption by up to 50 per cent. The reduction in speed results directly in a reduction of power, and therefore energy.

Long-term efficiency

Lastly, plant managers can improve motor efficiency by applying Industry 4.0 technologies like sensors that, when installed at various steps of a line, can support optimal efficiency in each stage of production. Dedicated sensor technologies, like WEG Motor Scan, can monitor a motor’s vibrations, heat and position to give plant managers a better understanding of the asset’s overall health and performance.

For example, if the sensor identifies excessive vibrations in a piece of machinery, then it might be a good idea to check the equipment’s mechanical strength in order to minimise the amount of wasted energy. Industrial sensors can also be used for condition-based monitoring that involves the use of sensors to track the health of equipment, and predict when maintenance is imminently needed. As well as monitoring motors, these sensor technologies can also be used on other assets including pumps, compressors and fans.

When selecting an efficiency-boosting add-on to an existing motor, plant managers must think about how it will impact efficiency in the long run. Fortunately, despite necessitating an initial investment, the three energy saving strategies outlined in the new Commission Regulation (EU) 2019/17 updates are likely to help manufacturers save money in the long-term. Plant managers can look at how much money they’re likely to save by upgrading their motors here with WEG’s payback tool. 

Business owners, especially the 20 per cent that expect the economic crisis to impact their enterprise more than the COVID-19 pandemic, will welcome new energy saving regulations that keep the costs of running a production line as low as possible.